Part 1: Custom Aluminum Fabrication - Applications and Material Selection

Part 1 of 3-Part Aluminum Fabrication Series.

When a leading industrial radiant heater manufacturer needed 600+ heat shields fabricated monthly from .020" aluminum, they discovered what many engineers learn the hard way: not all metal fabricators can handle aluminum's unique challenges. Custom aluminum fabrication demands more than standard metalworking equipment—it requires deep understanding of material behavior, specialized handling protocols, and process expertise that turns aluminum's distinctive properties into competitive advantages.

This three-part series explores aluminum fabrication from material selection through advanced techniques, helping engineers and procurement professionals make informed decisions for their next project. In Part 1, we'll examine aluminum's key applications across industries and guide you through critical material selection decisions.

Why Custom Aluminum Fabrication Matters

Aluminum's lightweight strength, corrosion resistance, and formability also makes it challenging to handle

Aluminum's combination of lightweight strength, corrosion resistance, and formability makes it indispensable across modern manufacturing. At one-third the density of steel while maintaining comparable strength-to-weight ratios, aluminum enables designs impossible with heavier materials. However, these same properties that make aluminum attractive also create fabrication challenges that separate capable shops from exceptional ones.

The difference becomes critical when projects demand:

• Thin-gauge fabrication (.020"-.050" thickness) without surface damage

• High-volume production maintaining consistent quality across thousands of parts

• Complex geometries requiring precise forming without material failure

• Food-grade or aerospace specifications with zero-defect requirements

Common Applications: Where Custom Aluminum Fabrication Excels

Automotive Industry Applications

The automotive sector increasingly relies on aluminum to meet fuel efficiency standards while maintaining structural integrity. Modern vehicles incorporate aluminum in:

• Body Panels and Structural Components: Aluminum reduces vehicle weight by 40% compared to steel equivalents, directly improving fuel economy by up to 20% through weight reduction alone.

• Engine Components: Transmission housings, cylinder blocks, and heat shields benefit from aluminum's thermal properties and weight advantages.

• Suspension Systems: Aluminum control arms and mounting brackets deliver strength without adding unsprung weight that compromises handling.

Recent fabrication projects demonstrate aluminum's automotive potential—from precision brackets for off-road step bars requiring exact frame mounting geometry to heat shields protecting sensitive components from radiant temperature extremes.

Aerospace and Aviation Components

Aerospace applications demand aluminum's exceptional strength-to-weight characteristics. Commercial aircraft construction utilizes up to 80% aluminum alloys by weight, with specific grades chosen for distinct requirements:

• Fuselage and Wing Structures: 2024 aluminum alloy provides excellent fatigue resistance for primary aircraft structures experiencing repeated stress cycles.

• Interior Components: 6061 aluminum offers good formability for brackets, mounting systems, and interior framework where moderate strength suffices.

• Structural Reinforcement: 7075 aluminum delivers maximum strength for load-bearing applications despite reduced weldability.

Food Service and Processing Equipment

Food industry applications leverage aluminum's natural corrosion resistance and non-toxic properties. Custom aluminum fabrication for food service includes:

• Prep Tables and Work Surfaces: 5052 aluminum provides excellent corrosion resistance to acidic foods and harsh cleaning chemicals while meeting NSF standards for food contact surfaces.

• Mobile Carts and Transport Equipment: Lightweight aluminum construction reduces worker fatigue while maintaining load capacity for commercial kitchen operations.

• Storage and Shelving Systems: Aluminum's corrosion resistance eliminates rust contamination concerns in humid food processing environments.

  
  

Learn more about our NSF-compliant food equipment fabrication capabilities.

Electronics and Telecommunications

The electronics industry exploits aluminum's thermal and electrical conductivity for:

• Heat Sinks and Thermal Management: Aluminum's thermal conductivity efficiently dissipates heat from electronic components, extending equipment lifespan.

• Enclosures and Housings: Lightweight aluminum enclosures provide electromagnetic shielding while simplifying installation and transport.

• Mounting Brackets and Structural Components: Precision-formed aluminum supports sensitive equipment without adding unnecessary mass.

Key Considerations for Choosing Aluminum

Aluminum Grades: Understanding Your Options

Selecting the appropriate aluminum grade fundamentally impacts fabrication success and final part performance:

• 5052 Aluminum:

  • Excellent corrosion resistance in marine and food service environments

  • Superior formability for tight bends and complex geometries

  • Good weldability with proper techniques

  • Typical applications: Sheet metal fabrication, brackets, food equipment, marine components

• 6061 Aluminum:

  • Good machinability for CNC applications

  • Heat-treatable for enhanced strength (T4, T6 tempers)

  • Moderate formability with appropriate bend radii

  • Typical applications: Structural components, machined parts, aerospace brackets

    
    

At MetalFab Group, we maintain extensive inventory of both 5052 and 6061 aluminum in various thicknesses (.035"-.500"), ensuring rapid project initiation without material lead time delays.

Aluminum's Unique Handling Requirements

Aluminum's soft nature—a benefit for formability and machining—creates unique challenges throughout the fabrication process. Surface damage from improper handling, scratching from contaminated equipment, or deformation during transport can compromise both aesthetics and function.

At MetalFab Group, aluminum handling protocols address vulnerabilities at every stage:

• Load/Unload Operations: Suction cup systems eliminate metal-to-metal contact during material loading and unloading, preventing surface marks from clamps or mechanical grippers that damage softer aluminum surfaces.

• Equipment Cleanliness: Laser beds undergo thorough cleaning between jobs, removing slag and contaminants from previous materials. Cross-contamination from steel or other harder materials can embed particles into aluminum surfaces, creating permanent blemishes.

• Inter-Process Transport: Custom pallets and specialized fixtures protect aluminum during movement between work centers. Standard racks designed for steel prove too aggressive for aluminum's softer surface.

• Surface Finishing Integration: Time Saver deburring machines remove sharp edges and surface irregularities post-laser cutting, delivering parts ready for finishing or assembly without secondary hand-work creating inconsistent surface conditions.

• Protective Measures: Factory-applied protective film remains in place throughout fabrication when specified, adding another barrier against handling damage during multi-operation processes.

Suction cups on the 2510 laser for special handling of Aluminum sheets

These systematic handling protocols prove especially critical for:

• Visible surfaces requiring cosmetic finish quality

• Anodized or powder-coated components where surface prep affects finish adhesion

• Thin-gauge aluminum (.020"-.050") where damage risks multiply

• High-volume production requiring consistent surface quality across quantities

Alternative Materials: Aluminum vs. Steel vs. Stainless Steel

Understanding when aluminum represents the optimal choice—and when alternatives perform better—ensures appropriate material selection:

Factor	Aluminum	Carbon Steel	Stainless Steel (304/316)
Weight	1/3 the density of steel (2.71 g/cm³)	3x heavier than aluminum (7.85 g/cm³)	Heavy (8.0 g/cm³)
Corrosion Resistance	Excellent - natural oxide layer protects surface	Poor - requires coating/painting	Superior - resists harsh chemicals
Strength	Moderate to good; Good strength-to-weight ratio	Higher absolute strength	High strength
Machinability	Excellent - machines 3-4x faster	Good - standard machining	Moderate - work hardening challenges
Formability	Excellent - tight bends possible	Good - requires larger bend radii	Good - requires more force
Weldability	Challenging - requires specialized equipment	Excellent - straightforward welding	Good with proper techniques
Thermal Conductivity	High - excellent heat dissipation (120-180 W/m·K)	Low - poor heat conductor	Low (16 W/m·K)
Cost	Moderate	Lower	Higher
Typical Applications	Lightweight structures (automotive and aerospace), thermal management (electronics), food service, general fabrication	Structural, heavy equipment, general fabrication	Food equipment, chemical processing, medical, marine

When to Choose Aluminum:

• Lightweight construction is critical (transportation, portable equipment, aerospace, automotive, portable equipment)

• Corrosion resistance requirements are moderate; but matters for application environment (marine, outdoor, food processing)

• Thermal conductivity provides functional or design advantages (heat sinks, radiators, electronics)

• Non-magnetic properties are essential (electronics, medical equipment)

• Machinability and formability simplify production (complex geometries)

• Anodizing finish is desired for aesthetics or enhanced protection

When to Choose Carbon Steel:

• Maximum structural strength outweighs weight considerations

• Cost sensitivity requires most economical material option

• Welding ease and reliability are paramount

• Higher hardness prevents surface damage in demanding applications

When to Choose Stainless Steel:

• Maximum corrosion resistance in harsh chemical environments (chemical processing, pharmaceuticals)

• High-temperature applications exceed aluminum's 400°F service limit

• Surface hardness prevents wear and abrasion (high-traffic equipment, cutting surfaces)

• Food-grade applications demand superior sanitary properties (commercial kitchens, food processing)

• Magnetic properties are required (some grades are magnetic)

  
  

Surface Finishing Considerations: Aluminum offers broader finishing options including anodizing (enhancing corrosion resistance and adding color) and chromate conversion coatings unavailable for stainless steel. However, stainless steel's inherent corrosion resistance often eliminates finishing requirements entirely, reducing total production costs for applications where surface appearance is secondary to function.

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What's Next in This Series

Now that you understand aluminum's applications and how it compares to alternative materials, Part 2 dives deep into the technical challenges of thin aluminum fabrication—including the specialized techniques required to fabricate .020" aluminum without surface damage at production volumes.

Coming in Part 2: Thin Aluminum Fabrication: Techniques, Challenges, and Solutions

• Material handling protocols for delicate thin-gauge aluminum

• Laser cutting and forming optimization

• Real-world case study: 600+ heat shields monthly

• Design for manufacturability guidelines

Ready to discuss your aluminum fabrication requirements? Contact MetalFab Group to explore how our material expertise and fabrication capabilities deliver results for automotive, aerospace, food service, and industrial applications.