In various industries, the choice of materials for manufacturing plays a crucial role in determining the cost-effectiveness of a project. When it comes to metal fabrication, aluminium extrusion has gained significant popularity due to its unique properties and cost advantages. In this article, we will explore the cost-effectiveness of aluminium compared to other metals commonly used in manufacturing processes.

What are the Cost Advantages of Aluminium Extrusion?

Material Cost

One of the primary cost advantages of aluminium extrusion lies in the relatively low raw material costs. Compared to other metals like steel, brass, or copper, aluminium is generally more affordable. This is due to the abundant availability of aluminium ore and the efficiency of aluminium production processes.

Production Efficiency

Aluminium extrusion processes are highly efficient, enabling manufacturers to produce large quantities of components within short lead times. The extrusion process allows for continuous production, minimising material waste and reducing labour costs associated with frequent setup changes.

Lightweight and Transportation Savings

Aluminium’s low density provides a significant cost advantage, particularly in industries where weight reduction is critical, such as automotive and aerospace. The lightweight nature of aluminium extrusions not only reduces material costs but also translates into savings during transportation, as less fuel is required to move lightweight components.

Design Flexibility and Simplified Assembly

The design flexibility offered by aluminium extrusion is a significant factor in its cost-effectiveness. Extrusions can be easily customised to meet specific requirements, eliminating the need for additional machining, or joining processes. By incorporating features such as integrated fastening elements, manufacturers can streamline assembly processes, reducing labour and material costs associated with secondary operations.

Corrosion Resistance and Maintenance Savings

Aluminium extrusions possess’ excellent corrosion resistance, making them ideal for applications where exposure to harsh environments is a concern. Unlike other metals, aluminium naturally forms a protective oxide layer, which helps prevent corrosion. This property reduces maintenance costs over the lifespan of the product, contributing to long-term cost-effectiveness.

So, How is Aluminium Extrusion Different to Other Metals?


As steel is a widely used metal, it generally requires additional surface treatment, such as galvanising or coating, to enhance its corrosion resistance. These processes increase costs and can negatively impact the environment. Aluminium extrusions, on the other hand, exhibit inherent corrosion resistance, eliminating the need for additional treatments and reducing overall expenses.

Brass and Copper

Brass and copper are widely known for their excellent conductivity and aesthetic appeal. However, both metals are considerably more expensive than aluminium. This is because they are both heavier, which can increase transportation costs. Aluminium extrusions offer comparable or better conductivity and can be surface-treated to mimic the appearance of brass or copper at a lower cost.


In conclusion, aluminium extrusion demonstrates remarkable cost-effectiveness when compared to other metals in various aspects. The efficiency of the extrusion process, minimal material waste, lower tooling costs, rapid prototyping capabilities, lightweight nature, corrosion resistance, energy efficiency and recyclability contribute to the overall affordability of aluminium extrusions.

Here at Simmal, we are an established provider of aluminium extrusion in its various forms. From large, single lengths to the manufacture of precision components, we have the know-how to help you complete your project. Contact our friendly team today for more information.

Contact us today about our services on 01772 324277

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