Engineering / Design Tips
| • | Know your Vendors and their Circle Size and/or other limitations like weight per foot, alloy, length of aging ovens, etc. |
| • | Compare your requirements for tolerances against the Aluminum Association Standards |
| • | Remember that tolerances for angularity, flatness and roundness will be reflected in the tolerances applied to various features. |
| • | Define and designate critical tolerances and features on prints. |
| • | Define and designate non-critical or non-functional features and apply appropriate tolerances. |
| • | Define and designate critical or exposed surfaces and related specifications or requirements. |
| • | Avoid webs or abrupt changes in metal thickness opposite critical or exposed surfaces. |
| • | Select appropriate alloy for the designated end use. |
| • | Design with surface finish in mind. |
| • | Round sharp corners: inside radii or corners .015 minimum and outside corners .020 minimum. |
| • | Use as large radii as possible in transition areas to make smooth transitions. |
| • | Keep wall thickness as uniform as possible. |
| • | Use built-in indexing marks to help in identifying symmetrical parts and to be used in locating holes, etc. |
| • | Screw bosses should have a 60 degree opening and wall thickness should be maintained as uniform as possible. |
| • | Use datums - do not double dimension |
| • | Remember that small details may become the controlling feature regarding extrudability. |
| • | Use AEC Engineering Services up front in design. |
| • | Fin ratio for heat sinks 4:1 up to 11:1 dependant on base thickness. |
Extrusion Design Options
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Design Aesthetics Into Extrusions
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Using the Extrusion Process for Net Shape
• Reduce the number of operations required
• Reduce the corner stress from bending
• Cosmetically more attractive
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4 operations |
1 operation |