Benefits of aluminium in buses
Aluminium is often considered a unique material, primarily for its low weight to high strength properties, however there are many other benefits that can be advantageous for modern buses and public transport.
Weight reduction
Using aluminium over other high strength metals can help reduce the overall vehicle weight which leads to lowered fuel consumption, increased passenger capacity and better driving performance.
Strength and durability
The high strength and energy absorption properties of aluminium enable buses to become safer for passengers, require lower maintenance and last longer.
Decarbonization and recycling
Aluminium from Hydro can help reduce the carbon footprint of new buses significantly when using our Recycled or Low Carbon products. Aluminium is also infinitely recyclable meaning buses are more sustainable at end of life, promoting circularity.
Shaping the future of buses through extrusion
Extrusion as a production method also has many benefits for creating structural applications in buses and large vehicles, when combined with the benefits of aluminium as a material you receive a unique combination of advantages.
Design flexibility
Our vast network of extrusion presses enables production of a wide range of profiles from simple flat sections to complex hollow shapes with built in functionalities.
Production efficiency
With innovative facilities combined with design support and extensive extrusion knowledge, extrusion by Hydro can boost production efficiency and reduce lead times and improving quality and reliability at high volumes.
Cost management
Using aluminium extrusion as a production method can reduce overall material consumption, increase reliability and be cost efficient due to long life times for the extrusion die.
From extruded aluminium profile to component
While simple, long length extruded profiles can find many applications in buses, using our in-house facilities for fabrication and value added services can transform a standard extruded profile into a ready to fit, assembled component.
Front and rear bumper systems: aluminium extrusion combined with bending, CNC machining, punching and welding.
Cross members and side sills: aluminium extrusion combined with CNC machining, punching, cutting and surface treatments.
Roof supports: aluminium extrusion combined with cutting, bending, CNC machining and punching.
Improve the efficiency of your aluminium components with Hydro
The most important phase of making buses lighter, safer and more sustainable with enhanced production efficiency remains the design phase. From initial material selection such as alloy grade and recycled content through to profile wall thicknesses and cavities, there are many factors that can help improve the efficiency and reliability of a structural component. Our design experts have over 50 years’ experience in making profile designs more efficient, enabling us to apply this knowledge to your next project.
Updated: May 6, 2025
