Aluminium Extrusion Tolerance

Aluminium extrusion is a popular manufacturing technique for the production of an extensive range of highly technical components for all types of industries. Extrusions offer complete accuracy for batch components which is particularly essential when manufacturing hundreds of profiles that are destined to be interconnected in a variety of projects such as shelving, window frames and construction applications. Engineers rely on a range of techniques to ensure that the accuracy of the profiles is maintained.

When Tolerance is applied

The extruding of aluminium profiles reaches a critical stage immediately after they emerge from the precision cut die which incorporates every furrow and ridge of the finished design. At this point the aluminium is still hot and malleable and vulnerable to becoming misshapen. If the extrusions become damaged in any way they lose their accuracy resulting in warped, twisted or bent profiles which are then unable to slot together. Window and door frames used for construction would be out of alignment and would have to be discarded. To prevent this engineers apply tolerances to keep the aluminium extrusion profiles in shape.

Tolerance Procedures

A range of measures need the correction of tolerance to ensure the aluminium extrusion profiles have a reliable accuracy. Engineers have to check for how flat the extruded profile is, how straight, curved where necessary and many other features. They have to use techniques that apply the correct tolerance to deliver complete accuracy. Feeler gauges are used to ensure a flat surface has been achieved. This usually involves placing the profile against a reliably flat surface such as granite blocks. If a right angle has to be created, the profile has to be measured against a set square gauge, feeler gauge and protractor. Any other sized angle can be manufactured but when assessing tolerance it must reach an accuracy of plus or minus one degree. There are also techniques and equipment for measuring the accuracy of the diameters of hole sizes in the profiles. Curved or bent profiles are common and have to be measured to achieve the correct curvature using a combination of bow measurers and feeler gauges.


Although much of the procedure involved in manufacturing aluminium extrusions is reliant on machinery and laser guided measuring equipment, there is still a need for the highly-skilled engineers at Edmo who are instrumental in producing profession profiles with accurate measurement and alignment.


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