Custom Aluminum Tubes - Special Shaped & Precision Design

Chalco special shaped aluminum tube product introduction

Common alloys used in the manufacture of special-shaped aluminum tubes: 6061, 6063, 6082, 7075, 2024, 5052, 5083, 3003, etc.

Processing methods of special-shaped aluminum tubes: extrusion, stretching, stamping, bending, flaring, welding, cutting

Customization of special-shaped aluminum tubes: size customization, shape customization, surface treatment customization, precision customization, etc.

Click to view [Detailed customization capability introduction]

Chalco special shaped tube product type

Chalco has a rich product system of special-shaped tubes, including a variety of complex shapes, covering a wide range of options from standard specifications to high-precision customization. With advanced extrusion technology and processing technology, these special-shaped tubes can meet the diverse needs of various industries for lightweight, high strength, corrosion resistance, etc., and are widely used in aerospace, automobile manufacturing, construction engineering, electronic appliances, medical equipment and other fields, providing customers with diversified solutions.

Aluminum special-shaped extruded section tube products

Aluminum special-shaped extruded tubes feature complex cross-sections like fan, teardrop, D-shape, and trapezoid, meeting multifunctional design needs for aerospace, automotive frames, and high-end industrial equipment.

Aluminum Sector Section Tube

Alloy: 2A12/2024 T4

Size: 61.53mm*34mm*1.5mm

Straightness: whole root ≤0.15mm,

Shape tolerance: ±0.1mm

Specification: GB/T6893-2010
Aluminum streamlined tube

Alloy: 2024 T3

Size: long axis 196.85mm* short axis 83.56mm* thickness 3.4mm

Specification: AMS-WW-T-700-3A

Application: Seaplane Wing
Aluminum D-Section Tube

Alloy: 6061 T6

Size: Height 50mm Width 30mm Wall thickness 2mm

Shape tolerance: ±0.2mm

Application: Communication equipment housing
Oval cross section tube

Alloy: 6063 T5

Size: Long axis 120mm; Short axis 60mm; Wall thickness 2.5mm

Shape tolerance: ±0.15mm

Application: Medical device bracket
Triangular cross section tube

Alloy: 7075 T6

Size: side length 100mm*wall thickness 3mm

Shape tolerance: ±0.2mm

Specification: ASTM B221-2021

Application: Aerospace structural parts
Trapezoidal cross section tube

Alloy: 6063 T6

Size: Upper base 40mm; Lower base 80mm; Height 50mm

Straightness: whole root ≤0.15mm,

Application: Industrial machinery support
Semicircular cross section tube

Alloy: 6061 T6

Size: diameter 100mm*wall thickness 2mm

Shape tolerance:±0.15mm

Application: lamps and decorative materials
Special-shaped aluminum square tube

Alloy: 6082 T6

Size: Side length 50mm; Wall thickness 3mm

Specification:EN 755-9:2008

Application: Construction and industrial framing
Inner shaped round tube

A tube with a circular exterior and a specific internal geometry (such as square, star, triangle, etc.). The internal structure can be customized to meet specific functional requirements.
Inner round outer shaped tube

While maintaining the internal circular cross-section, the external shape is designed with special shapes (such as rectangle, triangle, wave, etc.) to optimize the strength, stability and aesthetics of the pipe.

Aluminum alloy pipe bending products

Aluminum alloy elbows are designed with arc or custom bending, with excellent mechanical properties and fatigue resistance. They are ideal for automotive exhaust pipes, frame systems, fluid delivery pipelines and cooling systems.

Aluminum elbows

Alloy: 2A12/2024 O

Size: ∅ 90*5mm, ∅ 50* 5mm, ∅ 34*4mm

Specification: According to customer requirements
Aluminum bends

Alloy: 6061 T6, 5052 H32

Bending angle: 45 degrees, 90 degrees, 180 degrees

Curvature: Usually 1.5D to 3D, the curvature is relatively gentle.
Al mandrel bends

Bending angle: 30°, 45°, 60°, 90°, 180°

CLR: 1D, 1.5D or larger Precision bending, smooth tube wall.
Large diameter bends

Pipe diameter: 4 inches or larger

Designed for large diameter aluminum pipe, it provides smooth connections and precise bends for high flow piping systems.
Bending tubing for propane natural gas

Alloy: 5052 H32, 6061 T6

Size: ∅15mm- ∅50mm, wall thickness 1.5mm-4mm

Bending angle: usually 90° and 45°, supporting multi-segment bending.
Aluminum lighting fixtures

Alloy: 6063 T5

Highly reflective, it is an excellent choice for threading wires in lamps and fixtures.
Aluminum equipment handle

Alloy: 6061 T6, 5052

Bending: Usually U-shaped and C -shaped, the specific angle can be customized. Rugged and durable, it is widely used in medical equipment, industrial machinery and household appliances.
Large aluminum cooling coil

Alloy: 6061 T6, 3003 H14

Curved: Usually spiral, can be customized in many shapes.

Excellent heat dissipation and structural strength, used in air conditioning and refrigeration equipment.
Aluminum bent frame tube

Alloy: 6063 T5, 6082 T6

Diameter: ∅ 50mm- ∅ 100mm

Wall thickness: 2mm-6mm

Bending: Customizable bending angles, suitable for complex frame structures.
Foldable and bendable bicycle rack

Alloy: 7005 T6, 6061 T6

Tube diameter: ∅25mm- ∅50mm

Wall thickness: 1.5mm-3mm

Bending: Customized according to folding design to precisely match the connecting parts.

Aluminum telescopic pipe products

The aluminum telescopic tube is based on the round tube, and also has square, rectangular, oval and other cross-sections. Through the adjustable length telescopic design, it is lightweight and easy to carry, suitable for flexible scenes such as outdoor brackets, photographic equipment and medical equipment.

Telescopic tube for radar communication

Alloy: 2A12 T451

Size: ∅30.85*1.4mm-∅26.65*1.4mm- ∅22*1.4mm-∅16*1.4mm

Application: Radar communication
Aluminum telescopic pole for tent

Alloy: 6061 T6

Size: Ø28-Ø24-Ø20mm (telescopic section)

The tent stand is adjustable in length and highly portable.
Telescopic pole for outdoor equipment

Alloy: 7075 T6

Size: Ø32-Ø25-Ø19mm

Suitable for trekking poles, camping equipment and outdoor tools, high strength.
Aluminum telescopic antenna pole

Alloy: 6063 T5

Size: Ø40-Ø35-Ø30mm

Used for retractable communication antenna pole.
Telescopic rod for communication equipment

Alloy: 6082 T6

Size: Ø50-Ø40-Ø30mm

Communication tower pole, adjustable height, stable structure.
Thick-walled telescopic tube

Alloy: 5052 H32

Size: Ø60-Ø55-Ø50mm

High-load applications, including industrial supports and robotic arms.

Square/rectangular aluminum telescopic tube

Round aluminum telescopic tube

Oval aluminum telescopic tube

Eccentric aluminum telescopic tube

Single groove aluminum alloy telescopic tube

Streak aluminum telescopic tube

Aluminum tapered pipe products

The aluminum tapered tube, with one end larger than the other, optimizes fluid dynamics and is used in hydraulic pipelines, heat pipes, energy transmission, lamp posts, and weapons.

Aluminum tapered tube for weapon parts

Alloy: 5A06 O

Size: Ø200*10mm-Ø 150*10mm

Specification: GB/T6893—2010

Application: Parts of a certain type of weapon
Aluminum tapered tube for equipment support

Alloy: 6061 T6

Features: moderate strength, light weight, easy to weld.

Application: Industrial equipment support rods, robotic arms, etc.
Aluminum tapered tube for street light pole

Alloy: 6063 T 6

Big end: 180-240mm

Small end: 140-180mm

The wind resistance is improved, but the processing is complicated.
Large diameter aluminum tapered tube

Alloy: :5A06 O

Size: Ø200*10mm-Ø 150*10mm

Specification: GB/T6893—2010

Application: Parts of a certain type of weapon

Aluminum Shell Tube

Aluminum alloy shell tubes, with circular, square, or custom cross-sections, offer lightweight strength for protection and support. Used in electronics, motors, aerospace, and medical enclosures, they ensure vibration resistance, corrosion resistance, and precision for critical components.

Aluminum integrated shell and tube

Alloy: 5A06 H14

Size: 30*30mm-27*27mm *195mm

Inner hole tolerance: +0.2mm

Specification: Both parties draft a technical agreement
Aluminum motor housing

Alloy: 6061 T6

High strength, vibration resistance, easy to process. Used for industrial motors and household appliances motor housings.
Aluminum optical brazing protection tube

Alloy: 6082 T5

Size: Ø10mm-Ø20mm, wall thickness 0.8mm-1.5mm

Moisture-proof, corrosion-resistant, and high-strength, ideal for optical fiber protection and transmission.
Aluminum car/motorcycle exhaust pipe

Alloy: 6063 T5

Size: elbow or straight tube design, outer diameter and curvature can be customized.

Lightweight, high temperature resistant and easy to shape.

Aluminum heat dissipation and heat exchange aluminum tube products

Aluminum alloy heat sinks are represented by finned tubes or internal spiral grooved tubes. They combine excellent thermal conductivity and corrosion resistance and are core components in heat exchangers, refrigeration systems and power equipment.

Aluminum heat pipe

Alloy: 6061, 6063, 6005

Excellent thermal conductivity, suitable for efficient heat dissipation design. Used in electronic equipment radiators and power module housings.
Aluminum heat exchanger fin tube

Alloy: 1050, 1060, 1070, 1100, 5052, 6063

Excellent thermal conductivity and strong corrosion resistance. Used in heat exchangers such as industry and refrigeration.
IHX pipeline

Alloy: 1050 , 1060 , 1100 , 6061

Internal heat exchangers, coaxial exchangers: production and assembly of complete straight components.
Grooved pipe fittings

Alloy: 1050 , 1060 , 6063

The interior is designed with small diameter fin tubes to increase the exchange surface and internal fluid turbulence.
AC pipe

Alloy: 1050, 1060, 6061

Tubing designed specifically for applications requiring high heat exchange efficiency.

Aluminum tube with multi-barrel products

Aluminum alloy multi-cavity tubes have complex internal cavity designs, including symmetrical multi-cavity and special-shaped multi-cavity structures, which provide high strength and versatility while maintaining lightweight. They are widely used in aerospace frames, automobile chassis and precision instruments.

Double-barrel shaped aluminum tube

Lightweight double-cavity design offers strength, corrosion resistance, and thermal conductivity, widely used in automotive, aerospace, and refrigeration.
8 shape double barrel aluminum tube

The appearance is "8" shaped, with two pipes connected, and has good strength and bending resistance. It is widely used in pipeline frames, brackets, engineering machinery, etc.
Aluminum waist wheel tube

Alloy: 6063 6063

Size: According to drawings

Shape tolerance: ±0.03m

Application: Instrument measuring device assembly
Aluminum cylinder tube

Alloy: 6063 T5 T6 T832, 6061 T6511

Full range of standard size cylinder tubes in stock, hundreds of standard molds to choose from; in accordance with ISO 6430, ISO 6431, VDMA 24562, ISO 15552 …
Aluminum microchannel tube

Alloy: 1050, 1100, 3003, 6063, 6061, 3102

key components such as automotive air-conditioning condensers, evaporators, and oil coolers. The design of microchannel aluminum tubes is developing towards more channels and ultra-thin walls.

Aluminum high precision tube products

Specializing in high-precision aluminum tubes, we offer diameters from 0.094 inches with ±0.0005-inch tolerance, including telescopic, oval, and square shapes. Used in laparoscopic surgery, satellite cooling, and precision-demanding fields.

High precision reinforced tube

Manufactured with high-precision processes, offering excellent strength and durability, ideal for high-pressure and high-strength applications.
High precision capillary tube

Featuring extremely tight inner and outer diameter tolerances, widely used in precise liquid flow control and medical devices.
High temperature resistant precision tube

Providing exceptional high-temperature resistance, suitable for precision piping systems in high-temperature environments.
High precision seamless pipe

Made using seamless technology to ensure high precision and reliability, widely used in aerospace and precision industries.
High-precision multifunctional composite pipe

Combining multiple functional properties, ideal for complex structures and diverse industrial applications.

Chalco other aluminum alloy special-shaped pipe products

Aluminum trough structure tube

Alloy: 6061 6063

Featuring a channel-shaped cross-section, they offer enhanced load capacity and bending resistance, with various sizes and wall thicknesses for diverse structural needs.
Aluminum aviation duct

Alloy: 5A02, 5052, 2024, 5A06, 6061, 7075

Application: Suitable for complex machining, used in aerospace applications.
Aluminum liquid transport pipe

Alloy: 5052 H32

Size: Customized large diameter and long tubes.

Excellent corrosion resistance, suitable for a variety of liquid media.
Aluminum gas transport pipe

Alloy: 6061 5083

Size: ∅25mm-∅ 100mm, wall thickness 2mm-4mm

High air tightness, high pressure resistance. Used for industrial gas and medical oxygen delivery.
Aluminum fuel pipe

Alloy: 3003 H14

Features: Small diameter and high precision.

Leak-proof, corrosion-resistant, suitable for long-term use. Used in aviation fuel transportation, vehicle fuel systems.
Aluminum electrical conduit

Alloy: 6061 T6

Feature: high precision, high temperature resistance.

Offering excellent conductivity and corrosion resistance, ideal for power transmission and electrical systems.

Need other alloy special-shaped tubes?

Although our main product of Chalco Aluminum is aluminum, the group company is also involved in other metal fields and can provide a variety of metal products. If you have needs for other metal alloy special-shaped tubes, please feel free to communicate with our sales staff. We will do our best to allocate resources and provide you with the best solution. Quick Quote

Customized Titanium Alloy Tube

Custom steel pipe

Custom stainless steel pipe

Custom copper pipe

Custom brass tube

Custom composite pipe

Considerations in purchasing special-shaped pipes: reducing mold costs and reducing communication costs

We provide customized special-shaped pipe services to help customers save project funds and time costs by reducing mold costs and simplifying the customization process. When customizing special-shaped pipes, mold costs are usually the core of procurement. Traditional mold opening and custom molds often require high costs and time, affecting the budget and project schedule. Chalco has obvious advantages in molds:

Existing mold resources: Rich inventory of standard special-shaped molds, which customers can use directly without paying additional mold fees.
Free design optimization: Mold design support is available for special specifications, significantly reducing customization costs.
Free mold fee policy: For specific orders or batches, free mold fee discounts are provided to lower the purchasing threshold.
Simplified customization process: From demand communication to solution confirmation, to rapid prototyping and mass production, each step is efficient and convenient. After the customer provides the design requirements, we quickly optimize the solution and provide sample evaluation, ultimately ensuring the high quality and stability of each batch of products.
Advanced equipment ensures quality and quantity: We have industry-leading extrusion, drawing, welding, heat treatment production lines and CNC processing machinery to achieve efficient and high-precision aluminum tube production. We support seamless tubes, welded tubes and a variety of precision processing. Advanced testing equipment is used throughout the process to ensure that the products meet international standards.

capability

Chalco aluminum tube customization service

We are committed to providing customers with highly flexible and precise aluminum tube customization services to meet diverse industry needs. From design to production, our professional team collaborates to ensure that every aluminum tube can perfectly fit your application needs.

Size customization:

Diameter range: from micro tubes to very large diameter aluminum tubes
Wall thickness range: from very thin to very thick
Length selection: According to actual use, different lengths can be customized

Materials and performance customization:

Aluminum alloy types: Supports a variety of grades, including 1000 series to 7000 series, such as 6061, 7075, 5052, etc.
Mechanical properties: Optimize strength, hardness, corrosion resistance, thermal conductivity, etc. according to usage requirements
Surface treatment: anodizing, electrophoretic coating, powder coating, polishing, brushing, etc. to improve corrosion resistance, aesthetics and other properties

Functional requirements customization:

Our special-shaped aluminum tubes can provide customized functional solutions according to the needs of different industries to meet the special requirements of various fields.

Aerospace: Lightweight and high-strength aluminum tubes to meet high-strength and lightweight requirements
Automobile manufacturing: Aluminum tubes for cooling systems, transmission shafts and structural parts, with high temperature and pressure resistance
Engineering and construction: anti-corrosion structural parts and decorative pipes, with anti-corrosion layer treatment
Electronic appliances: thermal and electrical conductive pipes to meet high thermal and electrical conductivity functions
Medical equipment: precision delivery tubes and structural components with high precision and corrosion resistance

Aluminum shaped tube purchase detailed guide

1. What alloys are commonly used in custom extruded aluminum profiles?

When making custom aluminum tubes or special-shaped aluminum tubes, the following common aluminum alloys can be selected:

Aluminum 6063: Suitable for extrusion of complex designs and decorative purposes.
Aluminum 6061: A high-strength aluminum alloy with excellent weldability and extrudability, commonly used in structural parts.
Aluminum 7075: A high-strength aluminum alloy suitable for high-strength applications.

2. What are the key steps in custom extruded aluminum profile manufacturing?

Mould making: Design and make custom moulds according to customer requirements to ensure precise shapes and specifications.
Die preparation: Heat the die to the appropriate temperature and install it on the extruder.
Aluminum Billet Preparation: The aluminum billet is heated to between 750 and 930 degrees Fahrenheit to soften it for extrusion.
Extrusion process: Aluminum billets are compressed through a die and formed into the desired custom aluminum tube or shaped tube shape.
Cooling and cutting: The extruded tube is cooled and cut into the size required by the customer.
Subsequent processing: including straightening, aging, surface treatment and other steps to ensure the final quality.

3. Does it cost more to make custom extruded aluminum shapes?

Custom or shaped aluminum tubes usually cost more than standard products for a number of reasons:

Special mold manufacturing: Exclusive molds are required to meet customized needs.
Additional features or requirements: such as special size, complex design or surface treatment requirements.

4. What parameters should I specify when ordering custom aluminum extrusion profiles?

When ordering customized aluminum tubes or special-shaped aluminum tubes, customers should specify the following parameters:

Alloy type and tempering state
Size and weight requirements
Type of surface treatment (e.g. anodizing, polishing, coating, etc.)
Quantity and Shipping Tolerances
How to improve the strength and hardness of extruded aluminum profiles?
Heat treatment, such as tempering or aging, is a common method of increasing the strength and hardness of custom aluminum tubes.

5. Do you provide additional services for customized aluminum profiles?

We can provide a variety of additional services for customized aluminum tubes, including drilling, welding, anodizing, electrophoretic coating, polishing and customized packaging to meet customer needs.