Getting Started with Aluminum Extrusions

Learn how to design and assemble custom creations with aluminum extrusions for versatile and sturdy frames.

Aluminum extrusions, particularly T-slot extrusions, have become increasingly popular due to their widespread use in various applications, such as 3D printers, laser cutters, and CNC machines. Understanding how to design and assemble your own creations with these materials can open up numerous possibilities for custom projects. If you've ever played with a Play-Doh Fun Factory, the concept of extrusions will be familiar—material is pushed through a die to form a shape. While Play-Doh is child's play, aluminum extrusions typically use 6105-T5 aluminum, a common yet versatile material.

Why Use Aluminum Extrusions?

Building with aluminum extrusions offers several advantages. You can create frames for different projects, such as custom fixtures inside vans, workbenches, light fixtures, and even picture frames. Aluminum extrusions are strong, convenient, and relatively inexpensive. The basic tools needed include a saw to cut the extrusions to length and a drill for making holes. Sometimes, tapping holes is necessary, but overall, the process is straightforward.

Special Parts and Accessories

Working with extrusions requires various special parts, such as brackets, nuts, and other accessories. Think of it as an advanced Erector set for adults. Many of these parts can now be 3D printed, making the assembly process even more accessible and customizable.

Extrusion Geometry

There are different types of extrusions, but they generally share common features. Most extrusions are square or rectangular, with a central hole and T slots for attachments. Depending on your project, you might prefer extrusions without T slots on all sides for a cleaner appearance. Extrusions come in metric and inch measurements, with common profiles like 20x20 or 40x20.

Joining Extrusions

Joining extrusions securely and affixing components to them involves using special nuts and bolts. T-nuts, for instance, slide into the T slots and hold the components in place. Preset nuts and drop-in nuts are other options for easier assembly. Additionally, T-head bolts fit into the slots, providing a secure connection.

Connecting Extrusions

Brackets are essential for joining multiple extrusions. They come in various shapes, such as L, T, or plus signs, and materials like aluminum, steel, or polymer. You can also 3D print your own brackets. Using inner connectors can help align and secure the extrusions. For end-to-end connections, linear connectors are useful. Sometimes, tapping central holes and using bolts can provide a more streamlined connection without brackets.

Accessories for Extrusions

Many accessories are designed to work with aluminum extrusions, including cover plates, feet, casters, and springs for holding materials like acrylic. You can also find wheels, doors, handles, and hinges made to fit T slots. 3D printing communities offer designs for various accessories, such as spool holders, filament guides, tool holders, and lamps that fit into T slots.

In conclusion, aluminum extrusions offer a versatile and sturdy solution for numerous custom projects. By understanding the basics of extrusion geometry, joining techniques, and available accessories, you can unlock a world of possibilities for your next creation.