Aluminium profile design support

Whether you are developing a new aluminium component or optimizing an existing profile, Hydro's engineers help you move from concept to extrusion-ready design. We review geometry, tolerances, alloy selection, joining strategies, and surface finish options for extruded aluminium profiles across automotive, building, marine, transport, and industrial applications.

Talk to a design engineer

What you can design with aluminium profiles

Building and construction

Facade systems, curtain walls, structural framing, railing, and cladding profiles designed to meet appearance, corrosion, and load requirements. Aluminium's strength-to-weight ratio and recyclability make it a preferred material for greener building solutions.

Automotive

Structural components, crash management systems, battery enclosures, and EV platform profiles engineered for strength, weight savings, and volume production. Hydro supports design for manufacturability in automotive aluminium extrusions.

Marine and offshore

Profiles for vessel structures, deck systems, and offshore platforms where corrosion resistance, weldability, and structural performance are critical. Hydro's marine-grade alloys and design expertise support demanding maritime environments.

River and highway crossing a town, aerial view

Transportation

Lightweight profiles for rail vehicles, trams, buses, and freight systems. Aluminium extrusions help reduce vehicle weight while meeting structural and safety standards.

We also support aluminium profile design for HVACR, solar and energy, electronics, infrastructure, industrial design, and general engineering applications.

Have a product concept? Talk to a Hydro design engineer

How we support your design

Share your concept: Send a sketch, CAD file, or performance requirements.

Review with a Hydro engineer: We assess feasibility, flag manufacturability risks, and discuss geometry, wall thickness, tolerances, alloy options, and downstream operations.

Optimize the design: We suggest profile improvements for strength-to-weight, material use, joining strategy, and surface finish choices (anodizing, painting, powder coating).

Prototype and validate: Where needed, we support prototyping and sample validation before committing to full production tooling.

Move to production: Confirmed designs proceed to die manufacturing and extrusion. Learn more about custom-made dies.

What we review

Profile geometry and wall thickness feasibility
Tolerances: extrusion capability vs. machining requirements
Alloy selection and corrosion performance
Surface finish and appearance requirements
Joining and assembly strategy (mechanical fasteners, welding, adhesive bonding)

EcoDesign by Hydro

EcoDesign is a framework for making design decisions that reduce environmental impact across a product's lifecycle. For aluminium profiles, this means designing for disassembly, choosing alloys that support recycling, and reducing material use without compromising performance. Hydro's EcoDesign approach helps you meet EU requirements and build greener products from the start.

Extrusion Design Manual

For in-depth technical guidance on aluminium extrusion, explore Hydro's Extrusion Design Manual. Built on more than 50 years of experience, it covers 19 chapters from alloy selection and profile tolerances to joining methods, surface treatment, and structural calculations.

Profile Academy

If your team wants hands-on aluminium knowledge, Hydro's Profile Academy is a two-day training session led by product designers, metallurgists, and extrusion specialists. The programme is tailored to your needs and covers topics like tolerances, alloy properties, profile design principles, and how components fit together in practice.

Frequently asked questions about designing with aluminium

Can Hydro help with aluminium prototyping?

Yes. As part of the design review process, Hydro supports prototyping and sample validation to confirm that your profile meets dimensional, mechanical, and appearance targets before committing to production tooling.

What industries use custom aluminium profile design?

Aluminium profiles are designed and extruded for automotive (structural and crash components), building and construction (facades, framing, railing), marine and offshore (vessel structures, deck systems), transportation (rail, tram, bus), and many other sectors including HVACR, solar and energy, electronics, industrial design, and general engineering. Hydro supports design for all of these applications.

What is the Hydro Extrusion Design Manual?

The Extrusion Design Manual is a free online resource covering 19 chapters of technical guidance on aluminium extrusion. Topics include alloy selection, design advice, profile tolerances, joining methods, surface treatments, and structural calculations. It is available at hydroaluminiumdesign.com.

What is EcoDesign for aluminium profiles?

EcoDesign is a EU framework for reducing environmental impact through product design decisions. For aluminium profiles, this includes designing for disassembly, selecting recyclable alloys, and minimizing material use. Learn more about Hydro EcoDesign.

Request a design review