Big Enough To Cope, Small Enough To Care

Extrusion & Custom Design

Bring Us Your Idea and Let's Turn It Into a Sample

Every great aluminium profile starts as an idea. It might be a sketch on a notepad, a part that needs improving or a complete system that doesn't exist yet. At Extal, we help you take that idea and develop it into a practical, manufacturable extrusion solution.

Since 1996, Extal has provided a full range of aluminium extruded and roll form products. Our Extrusion & Custom Design service brings that experience together with hands-on design support and 3D-printed samples, so you can see, hold and test your concept before you go any further.

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Why Choose Us

From Concept to Practical Extrusion

Designing a custom extrusion is about more than drawing a shape. The profile needs to suit the alloy, the finish, the way it will be fabricated and the job it has to do once it is installed. We work with you from the first conversation to make sure your design is practical to produce and fit for purpose.

Whether you are a manufacturer developing a new product, a fabricator looking for a better way to build or a designer with a one-off concept, we are happy to assist with non-standard shapes, customer exclusives and new design ideas.

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Services

Our Extrusion & Custom Design Services

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Aluminium Extrusion Profile and System Support

Need a single profile or a set of profiles that work together as a system? We help you work out the shapes, connections and details your project needs, drawing on our extensive library of existing standard and miscellaneous sections. In many cases an existing profile from our catalogue can be used or adapted, saving you time and cost.

Design and Engineering Support

We help turn your concept into a clear, workable design. Together we talk through how the profile will be used, how it will be joined or fixed, what finish it needs and what alloy and temper will best suit the application.

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    Manufacturability Review and Design Optimisation

    A design that looks right on screen is not always the easiest to extrude. Your profile is reviewed for manufacturability and we suggest practical refinements, such as adjusting wall thicknesses, simplifying details or choosing a more suitable alloy, so the final extrusion performs well and is efficient to produce.

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      3D-Printed Samples and Prototypes

      This is where your idea becomes something you can hold. We produce 3D-printed samples and prototypes of your profile so you can check the shape, fit and function, share it with your team or customer and review the concept before proceeding further.

        Start With Our Existing Profiles

        Before designing from scratch, it is worth exploring what is already available. Our Extrusion Catalogue includes a wide range of standard sections, including flat bar, square bar, round bar, hexagonal bar, angle, channel, round tube, square tube, rectangular hollow sections, I-beams and tees.

        It also features a large range of miscellaneous sections used across many industries, from coolroom channels, handrails, balusters and glazing posts to louvre and sunscreen blades, sign frames, security door and window frames, marine sections, truck body profiles and floor planks. Each section is listed with its die number, dimensions and mass per metre, making it easy to reference when you talk to our team.

        Download Our Extrusion Catalogue

        Browse our full range of standard and miscellaneous sections, plus available alloys, tempers, lengths and finishes.

        Download Catalogue

        How It Works

        • Share Your Idea
          Send us a sketch, drawing, sample or simply a description of what you need.
        • Design and Review
          We work through the design with you and review it for manufacturability.
        • Print a Sample
          We create a 3D-printed sample or prototype for you to review.
        • Refine and Approve
          We make any changes needed until you are happy with the design.
        • Extrude and Finish
          Your profile moves into extrusion, with finishing and value-adding options available to suit your project.

        Extrusion Capabilities at a Glance

        Our Extrusion Catalogue sets out the alloys, tempers and options available for extruded aluminium profiles.

        • Alloys: 6063, 6060 (available on request, bending quality), 6106, 6005A, 6351, 6061 and 6082, covering general purpose and architectural through to semi-structural, structural and high structural applications.
        • Tempers: T1, T4, T5, T52, T591, T595 and T6, including bendable grades. Availability varies by alloy.
        • Lengths: Up to 14.5 m.
        • Finishes: Mill, powder coating and anodising, with over 700 powder coat and anodise options available through our finishing service.
        • Value Adding: Drilling, cutting, punching and more.

        We can help you choose the right alloy and temper for your profile.

        Why Choose Us

        Why Choose Extal for Custom Extrusion?

        • Experience You Can Rely On
          ‍          Established in 1996, Extal is built on decades of experience in aluminium distribution and sales.
        • Local and Overseas Mill Partnerships
          Our partnerships with local and overseas mills give you options and solutions that best suit your project and budget.
        • Support at Every Stage
          From design and sampling through to finishing and fabrication, we are with you from start to finish.
        • Finishing and Fabrication Options
          ‍          Combine your custom profile with our powder coating, anodising, cutting, punching and slotting services.
        • Big Enough To Cope, Small Enough To Care
          You deal with a team that takes the time to understand your idea and see it through.

        Get In Touch

        Contact Extal

        Have an idea for a new aluminium profile? Bring it to us and let's turn it into a sample. Fill in the enquiry form below to tell us about your design, request a 3D-printed prototype or find out more about our extrusion capabilities. Our team will be in touch.

        Prefer to talk it through?

        ‍Call: 02 9672 4771
        ‍
        ‍Visit: 30 Peter Brock Drive, Eastern Creek
        ‍
        ‍Opening Hours: Mon-Fri: 8am-4pm, Weekend: By Appointment

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