Custom Aluminium Extrusions, Profile to Finished Part
A good extrusion turns a cross-section into a strong, light, repeatable part. P&A International engineers a comprehensive range of standard and complex custom aluminium profiles — including shapes some extruders find challenging — with post-extrusion machining, anodising and fabrication managed end to end.
As an engineering-led contract manufacturer founded as an engineering consultancy, we assign one dedicated engineer from die design to free off-tool samples, then scale into volume through our vetted partner-factory network, where every supplier is ISO 9000 certified or better.
consultancy + manufacture
per project, end-to-end
before mass production
every supplier certified or better
one-off to high volume
What we deliver
Custom profiles
Solid, hollow and semi-hollow 6063 / 6061 profiles from your cross-section or DXF, or reverse-engineered from a sample.
Heatsink extrusions
High-aspect-ratio fin profiles for thermal management, cut, machined and anodised into finished heatsinks.
Anodising & finishes
Clear and colour anodise, powder coat, brushed and polished finishes — durable, cosmetic and corrosion-resistant.
Machining & fabrication
Cut-to-length, CNC machining, drilling, tapping, mitre cuts, bending and assembly into finished components.
Engineering capability
- Profile & die design — solid, hollow and semi-hollow sections
- Alloy & temper selection (6063, 6061, 6005, 6082)
- Reverse-engineering from a sample or legacy part
- Post-extrusion CNC machining, drilling, tapping and mitre cuts
- Anodising (clear / colour), powder coat, brushed and polished finishes
- Bending, forming, thermal-break insertion and assembly
- DFM review to keep the section extrudable and on-tolerance through finishing
- Free off-tool samples with quality-assessment reports before any volume order
At a glance
| Alloys | 6063, 6061, 6005, 6082 in T5 / T6 tempers |
| Sections | Solid, hollow & semi-hollow custom profiles |
| Finishes | Mill, clear/colour anodise, powder coat, brushed, polished |
| Fabrication | Cut-to-length, CNC machining, drilling, tapping, mitre |
| Forming | Bending, thermal-break insertion, assembly |
| Tooling | New dies or runs from existing dies |
| Samples | Free off-tool samples + quality-assessment reports before mass production |
| Quality | Every supplier in our network is ISO 9000 certified or better |
Why engineers & buyers choose PA
For design engineers
A true design partner — one dedicated engineer, profile and die strategy, wall-thickness and tolerance review, and finish selection. We shape the section early so it extrudes cleanly and holds tolerance through anodising and machining.
For purchasing
Low-risk scalability — free off-tool samples before mass production, new or existing tooling matched to your volume, target-cost DFM, a single point of contact, and a vetted ISO 9000+ partner network managed end-to-end by P&A.
3 easy steps to get started
Send us your section
Share a cross-section drawing or DXF, alloy and volume — or a sample to reverse-engineer. One dedicated engineer confirms the die strategy.
Proposed design & quote
You receive a proposed profile, die and finish strategy with indicative pricing — typically within 48 hours.
Samples & production
Free off-tool samples with quality-assessment reports. On approval, your profile is extruded, finished, machined, inspected and shipped through our partner network.
Applications
Frames & enclosures · heatsinks & thermal · LED lighting · rail, trim & architectural · industrial automation · renewable-energy & battery structures · consumer products.
Extrusion is one part of our aluminium capability. Explore the aluminium design & fabrication hub, our custom aluminium extrusion company page, custom heatsinks built from extruded profiles, and aluminium fabrication.
Designing a better extrusion
A few early decisions shape every profile — sharing this detail lets us quote and prototype faster:
| Alloy & temper | 6063 for the best finish and anodising; 6061/6005/6082 for higher strength and structural sections. |
| Wall thickness | Keep walls as uniform as possible; thin or uneven walls distort on quench and raise scrap. |
| Hollow vs solid | Hollow sections need a porthole/bridge die — higher die cost but big stiffness-per-weight gains. |
| Section size | The circumscribing circle sets the press and die; larger envelopes need a bigger press and cost more. |
| Finish | Flag cosmetic faces in the drawing; reserve tight tolerances for post-extrusion CNC. |
What to send us for a fast, accurate quote
The more of this you can share, the quicker we can return a proposed design and price:
- A cross-section drawing or DXF (or a sample)
- Alloy & temper if known (default 6063-T5)
- Profile envelope: width, wall thickness, length
- Finish — mill, anodise, powder coat, brushed
- Machining, cutting and fabrication requirements
- Target cost and annual weight or length
Working from a sample or legacy part is fine — our engineer will reverse-engineer the section and propose the best die and finish route.
📄 Download the aluminium extrusion RFQ checklist & selection quick reference (PDF)
Get a quote
Send your section drawing, DXF or sample and one dedicated engineer will reply — typically within 48 hours — with a proposed profile and indicative pricing.
One dedicated engineer reviews every enquiry and replies with a proposed design and indicative pricing. Your details are used only to respond to your enquiry. Prefer email? support@pa-international.com.au