Understanding the differences and selecting the best aluminium profiles – find out which type is most appropriate for your specific project.
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Screws instead of welds, aluminium instead of steel! This was the revolutionary idea of the two founders of item, Gerrit Pies and Wolfgang Rixen, that kicked off the success story of the modular item Building Kit System for aluminium profiles in 1980. The benefits are low weight combined with maximum stability, rapid assembly thanks to innovative fastening technology, cost savings compared to steel and decisive flexibility. All these advantages are currently available across more than 4,500 mutually compatible components – and the range is continuously expanding. What’s more, the anodized aluminium profiles from item have inclined groove flanks. When fasteners are used in the groove, the groove flanks press against the fasteners in the elastic range, creating additional pre-tensioning that ensures the fasteners are even more secure. When it comes to vibrations in a machine base, for example, this represents a key advantage. These days, the modular profile technology from item is used in all kinds of projects by engineers around the world, ranging from simple frames to fully automated production lines.
However, what types of item aluminium profiles are there? What are the differences between them? And which aluminium profile is best used to meet which requirements? This post addresses these questions for newcomers to the world of item. In addition to the “classic” aluminium profiles, that is to say, the construction profiles, there are also other types – Line X and the profile tubes of Profile Tube System D30. Profile KH, on the other hand, offers a metal-free, sustainable alternative to aluminium profiles, and is also used for EMC applications. You’ll find more information about this special profile in an interview on our blog.
Differences at a glance: Aluminium profile types and their primary characteristics
The aluminium item construction profiles can be divided into five different types (item calls these lines): Line 5, 6, 8, 10 and 12. These different aluminium profiles are designed to meet different user requirements. Three geometric characteristics help to meet different needs, and all the lines differ in respect of the following:
- Modular dimension: Each line is based on mostly square profiles with an external dimension of 20, 30, 40, 50 or 60 mm. Continuous grooves run along all four sides.
- Groove dimension: The size and load-carrying capacity of the groove increase in line with the modular dimension. Most profile connections are anchored in the groove. The groove also serves as an anchor point for panel elements.
- Bore diameter: The core bore offers a stable fastening point at the end faces of the aluminium profiles. This bore can be used as a basis for subsequently tapping a thread.
In addition, there are different designs within the lines: Standard, Light and Economy. “Standard” speaks for itself. “Light” profiles are lightweight, while “Economy” profiles have a material-optimised design. In each of the two latter designs, the maximum tensile loading of the profiles is reduced. One particularly practical feature is the profile deflection calculator available alongside each aluminium profile in the item Online Shop.
It must be noted, however, that not every aluminium profile is available in all three designs. Fundamentally, item aluminium profiles are always described using the following pattern, in the item Online Shop, for example. Profile 8 40×40 1N light, natural. These descriptions can be deciphered as follows:
Compact aluminium profiles for precision work – Line 5
Line 5 aluminium profiles with a modular dimension of 20 mm are ideal for weight-optimised constructions of all kinds. Line 5 profiles can be used to create refined, stable and flexible applications. The small exterior dimensions make these profiles particularly well suited for space-saving and compact jigs, covers and handling equipment. Their low material consumption also mean they conserve resources. Line 5 aluminium profiles are available with open or closed grooves. A closed groove eliminates the problem of dirt accumulation in grooves.
The lightweight alternative: Line 6 aluminium profiles
Line 6 profiles with a modular dimension of 30 mm are ideal for all kinds of weight-optimised constructions. Using these aluminium profiles makes it easy to adapt the use of materials to the task at hand and rely on a slimline, robust design. Again, open or closed grooves can be used. The latter are easy to clean and also have a particularly elegant aesthetic. Line 6 profiles create functional and attractive display cases, tables and cover hoods.
Universal and robust all-rounder: Line 8
Line 8 profiles with a modular dimension of 40 mm are the most frequently used of all the item aluminium profiles worldwide. Their great versatility makes Line 8 profiles the perfect choice for machines and systems of all sizes. Thanks to their design, these aluminium profiles are light and robust, offering a wide range of uses with a service life of many years. This robust aluminium profile for load-optimised constructions is available with open or closed grooves. Profiles with closed grooves are particularly easy to clean and can be combined with conventional profiles as required. Line X (more about this further down) uses the Line 8 profile groove.
Increased load-carrying capacity for robust constructions: Line 10
Line 10 profiles with a modular dimension of 50 mm are ideal for load-bearing profile constructions. The 10 mm groove width makes it possible to work with accessories with thread size M10. This increased load-carrying capacity can be fully utilised thanks to the strong groove flanks. The fasteners also play a part in this. All Fastening Sets 10 consist entirely of high-performance steels so that pre-tensioning is always available in full. As a result, there is reliable protection from loss of preload. The maximum permissible load-bearing capacity is 7000 N. Various different cross-sections are available for Line 10 aluminium profiles. The weight-optimised Profiles 10 E can be used in areas involving lower loads. The end faces and the grooved sides of the aluminium profiles can be closed using matching plastic caps and cover profiles.
The robust option for load-carrying applications: Line 12 aluminium profiles
When it comes to creating stable, heavy-duty frame structures, Line 12 profiles with a modular dimension of 60 mm are the ideal choice. This is the strongest profile line in the item Building Kit System. Thanks to the strength of the profile flanks, tensile loading of up to 10,000 N per screw connection is possible. What’s more, the incline of the aluminium groove flanks down into the groove ensures excellent resistance to loss of preload. If areas of the basic frame are only placed under lower stress, the light version of Line 12 can be used.
Optimised form for elegance and cleanliness: Line X
Constructions based on Line X exhibit the best possible combination of elegance and cleanliness. A minimised edge radius results in a seamless connection between the profiles, with no protruding edges. This produces constructions that are easy to clean, where dirt and deposits have no chance of accumulating. These aluminium profiles are therefore perfect for building machines and systems that need to be kept spotlessly clean. Line X aluminium profiles are available with open or closed grooves. The variants of Line X profiles with closed grooves are ideal for use in cleanroom production.
Profile tubes for lean factory equipment: Profile Tube System D30
Alongside construction profiles, profile tubes are another popular type of aluminium profile. Profile Tube System D30 has been specifically designed to meet the requirements of the fast, sophisticated and solution-oriented factory equipment engineering typical of lean production. The system’s (Profile) Tubes D30 can easily be cut to the desired length and connected using fasteners. Up to four fasteners can be connected to the same intersection point on a Profile Tube.
A special geometry is what makes the aluminium profile tubes so efficient. Four slimline, undercut flanks are enveloped by Fastener D30. Depending on the direction, the fastener is mechanically locked, but its connection is friction-based in the main load direction.
A special geometry is what makes the aluminium profile tubes so efficient. Four slimline, undercut flanks are enveloped by Fastener D30. Depending on the direction, the fastener is mechanically locked, but its connection is friction-based in the main load direction. Struts can be attached separately on each of the four sides. One person working with a single tool can make all the necessary connections. The five colours of Profile Tubes D30 provide quick orientation and help to clearly differentiate between areas or frames. The silk-matt powder-coating is abrasion resistant, and the anodized Profile Tube D30 and the black powder-coated Profile Tube are both ESD-safe. There are three standard lengths for the anodized Profile Tube D30 – 3000, 4000 and 6000 mm. Alternatively, a custom cut-off that has been sawn to size with millimetre precision can be ordered.
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The versatility of aluminum is well documented; from its lightweight to affordability, ease of machining, and environmental friendliness, aluminum has been successfully used in many industries. Industrial aluminum profiles refer to the aluminum material suitable for use as a main component in industrial aluminum extrusion processes.
In the extrusion process, the chosen aluminum bar is extruded by melting the material forced into a particular die with the desired section shape. The mechanical and functional properties of the finished product depend on the selected aluminum profile. What factors then make one aluminum profile more suitable than another? These seven factors and considerations are used to highlight the differences:
1. Strength
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Strength or durability refers to the ability of the aluminum profile to withstand pressure, damage, wear and tear that arises from the day-to-day use of the part as intended. It also refers to the ability of the part to withstand pressure and heat treatment. The maximum tensile strength is the amount of stretch or pulling the profile can take before its mechanical properties are permanently altered.
Generally, pure aluminum 1100 has the lowest strength, while the heat-treated alloy series of 2024 and 7075 are progressively higher in strength. The 5052 and 6061 offer medium to high mechanical strength.
2. Hardness
Hardness is different from the aluminum profile strength and is a factor in the aluminum profile’s chemical composition. The state of the aluminum profile also has a profound influence on the hardness of the profile.
The hardness matrix decreases from the 7 to 2,4,6,5,3 and 1 series in that order.
3. Corrosion Resistance
Corrosion resistance speaks to the ability of an aluminum profile to withstand the chemical changes to its structure arising from exposure to chemical and rust conditions.
In this case, the best corrosion resistance is seen in the 1 series. Next is the 5 series, then comes the 3, 6, 2 and 7 series in that order. In clearer terms, the Alloys 1100, 5052, and 6061 have excellent to very good mechanical properties, the 3003 and 6063 have decent corrosion resistance, while the 2 series is generally poor.
4. Weldability
Weldability refers to how easily an aluminum profile can be welded. The weldability of most aluminum profiles is generally very good. However, profiles of alloys 2024, 7075, and 2011 are inferior. Alloys 3003 and 1100 have excellent welding performances. The 5 series of aluminum profiles are particularly designed for welding.
5. Machinability
Machinability performance entails the ease of forming and machining an aluminum profile. This includes cutting, forming, and turning in some instances. Generally, the machinability of each aluminum profile may be affected by heat treatment or annealing. Annealed parts are very machinable and formable, while heat-treated aluminum materials are more challenging to machine. The alloys of 2011 are excellent for machining, by the 1100, 3003, and 6061 alloys.
6. Finishing
Aluminum profiles may be coated, anodized, polished and more to obtain the desired feel, look and finish. Depending on the end-use and environmental conditions where the part may be deployed, the aluminum profile for extrusion may need specific chemical and surface treatments to deliver on performance expectations.
7. End-use
By research and experience, certain aluminum profiles are more suitable for some industries than others. For instance, the Aluminium alloy 2011 and 1100 are broadly used in general machining and metal spinning, while the 2024 and 7075 are deployed in metal spinning and aerospace industries respectively.
Aluminum alloys 3003 are widely used to fabricate food and chemical equipment, while the 5052 alloys are applied in marine fabrications. Alloys 6063 and 6061 are best suited for structural and architectural applications.
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Our in-house capacity can deliver quality, avoid defects like burrs and flashes and facilitate low-volume manufacturing at affordable rates. Our other portfolio of services covers 3D printing, urethane casting, injection molding, and CNC machining.
If aluminum extrusion is one of the services you’re looking to secure in manufacturing your parts, please get in touch with us to get a free quote from our expert engineers and design inspection to get started on your project.
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