Star Extruded Shapes, Inc. is a complete aluminum extrusion provider. Not only do we extrude, we also provide aluminum fabrication, powder coating, assembly, and other finishing services. At Star, we pride ourselves in our ability to provide turnkey solutions for all of your aluminum extrusion needs.

Aluminum Extrusion Benefits

Lightweight
Aluminum is 1/3rd the density of steel, which makes aluminum an excellent choice for many motion- related applications. The benefit of an extruded aluminum section is that it puts material only where it’s needed, potentially reducing weight and costs.
Strong
Aluminum has a higher strength-to-weight ratio than many other materials. For example, 6061-T6 grade aluminum is nearly four times the strength of 304 stainless-steel; that makes extruded aluminum a good choice in load-bearing applications, where weight minimization is critical.
Non-corrosive
When Iron oxidizes it will rust and flake away, but when aluminum oxidizes it forms a protective film over the surface. That can save on the expense of a coating processes and eliminate maintenance when there is no need for a highly cosmetic finish.
Easy to work with
Most grades of aluminum machine easily. You can cut aluminum extrusion to length with a hacksaw and drill holes with your cordless drill. Using aluminum extrusions over other materials can save wear and tear on your machines and tooling.
Multiple finishing options
Extruded aluminum can be painted, plated, polished, textured and anodized. This gives you a multitude of options to choose from than there is possible with other materials.
Recyclable
There is a market value for scrap aluminum. That means when your product reaches the end of its lifecycle there are no issues with disposing of unwanted material.
Inexpensive tooling
When designers think about using extruded aluminum, they’ll often restrict themselves to the shapes available in catalogs of standard products. That can be a missed opportunity for design optimization, because custom extrusion tooling is surprisingly inexpensive.

Aluminum Extrusion Capabilities

We offer a wide range of aluminum extrusion services while preserving ISO 9001:2015 certifications across all of our manufacturing facilities. Our 165,000-square-foot extrusion plant features three aluminum extrusion presses (6”, 7” and 8” in diameter), allowing us to service many industries and their unique needs. The versatility of presses available provides Star the unmatched ability to manufacture profiles of all different sizes.

Aluminum Extrusion Process and Design

The extrusion process involves heating the raw material (billet) and the tooling (die) simultaneously. The die is loaded into the press where the billet is then pushed through the die to form the shape. Once extruded, the material is cooled, stretched and then cut to size at the extrusion press. The material then gets transferred and staged for the tempering process – a process that uses a heat treat oven to achieve the desired hardness required. From there, the parts will either get packed for shipment or sent to our fabrication or powder coat assemblies for final fabrication or finish required.

Our experienced staff of engineers are ready to assist you with your design needs. Using the most advanced software applications, including computer-aided design (CAD) and computer-aided manufacturing (CAM) programs, we can help you design the extrusion that will work best for your application.

Aluminum Extrusion Services

  • ISO 9001:2015 certified
  • 6000-series aluminum alloys
  • Standard and custom profiles
  • Multiple direct extrusion presses
  • Nitrogen-ported dies
  • Closed loop extrusion speed controls
  • Weight-per-foot range of 0.033 to 8 lbs.
  • Circle size up to 8 inches
  • Automatic run-out table
  • Extrusion recipe system setting
  • Belt handling systems
  • Water wall quench and over/under cooling

Contact us today for all of your aluminum extrusion needs!