What are its advantages?

It offers strength, flexibility, corrosion resistance, and lightweight properties.

Which industries use extrusion?

Construction, automotive, aerospace, renewable energy, and industrial sectors use extrusion.

What is VAEC’s capacity?

VAEC produces around 30,000 tons annually.

What sizes are available?

Profiles up to 450mm solid and 400mm hollow are available.

Aluminium Extrusion | VAEC Manufacturer India

Precision Extrusion Engineering

End-to-End Control. Scalable Manufacturing.

At VAEC Aluminium Extrusion Pvt Ltd, our aluminium extrusion process is designed to meet the highest standards of industrial performance, dimensional accuracy, and application-ready quality. Backed by state-of-the-art infrastructure, simulation-driven tooling, and strict process controls, we deliver custom aluminium profiles trusted by OEMs, architects, and engineers across construction, automotive, aerospace, defence, renewable energy, and electronics.

Aluminium extrusion is a precision manufacturing process where a heated aluminium billet is forced through a hardened steel die to create a continuous profile with a consistent cross-sectional shape. This allows for the production of complex, lightweight, and high-strength components that meet both structural and aesthetic needs.

VAEC specialize in:

Solid aluminium profiles up to 450 mm

Hollow aluminium profiles up to 400 mm

Extrusions with tight tolerances of ±0.4 mm (solid) and ±0.5 mm (hollow)

Custom and standard profiles for high-load, high-precision, or corrosion-resistant applications

VAEC Extrusion Infrastructure

5 advanced extrusion presses, ranging from 10 MN to 32 MN

3 Billet Casting Lines

In-house Die Shop with QForm simulation software

2 Modern Plants with full machining, finishing & quality control lines

This setup gives us the ability to meet diverse industry requirements across India and international markets, offering short lead times and dependable scalability.

Why VAEC’s Extrusion Process Stands Out

Fully integrated plant: From billet casting to die making and finishing, all under one roof

Ready-to-ship inventory: 8000+ die designs for quick order fulfillment

Fast turnaround: Custom die in 2 to 3 weeks, high-speed production

Sustainable process: Energy-efficient practices and recyclable alloys

Custom engineered profiles for structural, load-bearing, decorative, or thermal applications

BIS-certified production with ISO-grade quality systems

VAEC Aluminium Extrusion Process

1. Billet Casting

Our in-house casting facilities produce high-quality billets in sizes from 5 inches to 12 inches in diameter, and lengths up to 6000 mm, using primary and recycled aluminium alloys as per client specifications. Strict metallurgical controls ensure consistency and cleanliness, which are critical to the extrusion quality.

2. Billet Heating

The aluminium billets are heated to around 450–500°C to soften the metal for extrusion. Temperature control is crucial to achieve uniform flow, avoid surface defects, and maintain mechanical properties.

3. Die Preparation & Simulation

We design and manufacture our own dies using QForm simulation software. This virtual process flow modelling ensures accurate die design, balanced material flow, and optimized tooling life.

Production Capacity: 120 dies per month

Die Library: 8000+ ready dies for immediate use

Lead Time: Just 2–3 weeks for new custom dies

4. Extrusion Pressing

The heated billet is pushed through the steel die using one of our hydraulic extrusion presses (10 MN to 32 MN). This forms a continuous profile in the desired cross-section.

We maintain real-time monitoring of pressure, speed, and temperature to ensure dimensional accuracy and product integrity.

5. Quenching & Cooling

Immediately after extrusion, the profile is cooled using water or air (depending on alloy and specification) to lock in mechanical properties and minimize warping.

6. Stretching & Straightening

The extruded aluminium is stretched to relieve internal stresses and ensure straightness. This critical step improves profile geometry, structural strength, and handling safety.

7. Cutting to Length

Profiles are cut to customer-specified lengths for ease of transport and integration into assembly lines. Typical lengths range from 3 to 6 meters, though custom cuts are available.

8. Heat Treatment

Certain applications require T4, T5, T6, or other tempers. Our in-house aging ovens carry out heat treatment processes to enhance hardness, tensile strength, and thermal resistance.

9. Surface Finishing

We offer post-extrusion finishing processes based on your design needs:

Anodizing for corrosion resistance and matte finish

Powder Coating in a wide range of colours

Mechanical Brushing, Polishing, Sandblasting

10. Final Inspection & Packaging

All finished extrusions undergo strict dimensional checks, mechanical tests, and surface quality assessments. We follow BIS standards and international tolerances to ensure defect-free delivery.

Aluminium Billets for Diverse Industrial Needs

Our aluminium extrusion process supports precision-critical applications in:

EVs and Automotives: Crash beams, battery enclosures, chassis

Architecture & Building Systems: Facades, glazing systems, modular framing

Solar & Renewable Energy: Mounting structures, inverter frames

Aerospace & Defence: Lightweight brackets, enclosures, structural panels

Transport & Railways: Metro coach profiles, trailer components

Electrical & Electronics: Heat sinks, busbars, control boxes

Need Aluminium Extrusion Solution That Perform?

Partner with India’s Premier Aluminium Extrusion Manufacturer

Whether you’re designing the next generation of electric vehicles or need high-tolerance architectural frames, VAEC Aluminium Extrusion Pvt Ltd is your trusted partner for scalable, custom aluminium profile production.

Frequently Asked Questions

1. What is aluminium extrusion?

Aluminium extrusion is a manufacturing process where aluminium is heated and pushed through a die to create profiles with specific cross-sectional shapes used in industrial and structural applications.

2. What are the advantages of aluminium extrusion?

Aluminium extrusion offers high strength-to-weight ratio, corrosion resistance, design flexibility, and excellent thermal and electrical conductivity, making it ideal for various industries.

3. What industries use aluminium extrusion profiles?

Industries such as construction, automotive, aerospace, renewable energy, electrical, and industrial machinery widely use aluminium extrusion profiles.