Machining, forming and fabrication of aluminium extrusions

Name: Machining and fabrication
Brand: Hydro
Price: Contact for pricing USD
Availability: InStock

Hydro machines, forms and fabricates extruded aluminium into production-ready parts, using CNC machining, punching, bending, hydroforming, welding and finishing. Contact us to discuss your design and requirements.

Contact us to discuss your design possibilities and needs

Forming aluminium extrusions for complex geometry

Aluminium's formability makes it possible to create complex parts without adding weight. We use forming methods including hot gas forming, hydroforming, stretch forming and bending, supported by simulation and testing, to achieve high dimensional accuracy.

Mechanical joints vs welding

Extruded aluminium profiles can be designed for efficient mechanical joining. Mechanical joints are often simple to assemble, some can even be completed by the end user, and allow surface finishing on long lengths before cutting, reducing cost. Another advantage over welded joints is that surface finishing of profiles can be carried out on long lengths, thus reducing costs. Contact us to discuss joining options for your design.

CNC machining and punching

Aluminium profiles can be designed to need minimal machining after extrusion, but some processing is often required. Machining aluminium is relatively inexpensive: its malleability keeps tool costs competitive, and higher cutting speeds than steel keep machining costs low. Contact us to discuss your machining requirements.

Hydroforming and bending

Hydroforming is a process that uses internal fluid pressure to form an aluminium tube into a complex three-dimensional shape in a single operation. Bending shapes profiles and tubes along defined radii using stretch bending, roller bending, press bending or draw bending, the most widely used method, offering tight radii and good repeatability. Contact us to discuss hydroforming or bending for your part.

What is hydroforming?

A metal-forming process that uses internal fluid pressure to press an aluminium tube outward into a die, producing a complex three-dimensional shape in one operation.

What is the difference between hydroforming and bending?

Bending changes curvature along a tube's length; hydroforming reshapes a full three-dimensional geometry, including features bending cannot produce.

Can any aluminium tube be hydroformed?

Suitability depends on alloy, wall thickness, diameter and target geometry. Contact us with your tube dimensions and required shape.

Added-value machining: from profile to part

When you order extruded profiles from Hydro, you can add value with machining operations such as sawing, turning, drilling, milling and threading, as well as deburring and punching. Punching can include hole-cutting, cutting out blanks and cutting off lengths.

machining of aluminium extrusions

Additional services beyond extrusion

Beyond extrusion, we offer finishing, joining, assembly and logistics services so you receive parts ready for your production line or project.

Lacquering	Lacquering adds durable colour and surface protection to aluminium profiles and parts, with resistance to UV, corrosion, impact and abrasion.	Anodizing	Anodizing is an electrolytic surface treatment that hardens and protects the aluminium surface while giving a natural metallic feel. It resists corrosion and wear, with a range of colour tones available.
Crimping / Barrettage	Crimping (barrettage) joins aluminium profiles with polyamide bars to create a thermal break, useful for building applications requiring improved thermal performance.	Cut to length	We cut extruded aluminium profiles to length, from 5 mm pieces to lengths of up to 12 metres, to match your assembly or delivery needs.
Machining	Our CNC machining capability, including 5-axis machining centres, handles parts from small automotive components to multi-metre building-industry profiles, and can multiply the functions integrated into a single profile.	Punching	Punching is fast and cost-effective for large series production, using dedicated tooling for shearing and cutting.
TIG / MIG welding	6000-series aluminium alloys weld well using TIG or MIG processes, and extrusion design can integrate features that make welding easier.	FSW welding	Friction stir welding (FSW) joins aluminium by mixing the material with a rotating tool rather than melting it, giving a homogeneous, flush weld with reduced distortion and strong thermal performance.
Bending	Bending method depends on bend radius, profile shape, appearance and production volume. We offer draw bending, stretch bending, roller bending, and press bending.	Mounting and assembly	We can assemble your components before delivery, from gasket installation to crimped threaded inserts, so you receive a finished, ready-to-install product.
Kitting	We can prepare your parts in kits tailored to your specifications, including protective film, labelling, and screw-bag inclusion.	Storage	We can store your profiles under agreed conditions and release them according to your supply schedule.