At TOS – Technical Outsource Solutions, we support companies in developing and producing high-quality extrusion profiles. Extrusion is the technology for creating complex aluminum and metal profiles with precision and cost-efficiency.
We advise on material selection, tolerances, and finishing, and support with 3D drawings and prototyping . Thanks to our international network of reliable partners, we offer competitive prices, short lead times, and the flexibility to produce both small and large series.
With TOS you choose a single partner who controls the entire extrusion process – from design to post-processing and assembly.
Extrusion is a production technique in which a metal or plastic billet is forced through a die under high pressure. This creates profiles with a consistent cross-section, ideal for applications in industry, construction, and product development. Aluminum, in particular, is widely used due to its favorable strength-to-weight ratio, corrosion resistance, and recyclability. Common alloys are the 6000 series (such as EN AW-6060, 6061, 6063, and 6082) for structural and decorative applications, and the 7000 series for profiles requiring extra strength.
After the extrusion process, the profile can be further refined through CNC machining . This includes milling, drilling, or tapping holes for mounting or assembly. This allows extrusion profiles to be fully tailored to your final product.
In addition, surface treatments are essential for improving both functionality and appearance. Anodizing applies a protective oxide layer that is wear-resistant and provides a high-quality finish. Powder coating offers a wide range of colors and an additional layer of protection against external influences.
At TOS – Technical Outsource Solutions, we manage the entire process: from extrusion and CNC machining to anodizing and powder coating. This means you have a single partner for a complete and high-quality end product, tailored to your needs and specifications
During this conversation we will briefly explain what we can do for you and answer your questions.
Based on your product and requirements, we request prices and delivery times from various suppliers.
We will then prepare a clear quote. Prices are quoted based on your terms and conditions.
Once you have approved our proposal, we will start making a prototype.
After approval of the prototype, the assignment will begin.
Extrusion is primarily used with aluminum, thanks to its favorable strength-to-weight ratio, good formability, and excellent recyclability. Within aluminum, there are various alloys, each with its own advantages. The 6000 series (such as EN AW-6060, 6061, 6063, and 6082) is very popular: these alloys combine good mechanical properties with excellent corrosion resistance and are ideal for anodizing . The 7000 series is chosen for applications requiring extra strength, such as in construction or transportation equipment. At TOS – Technical Outsource Solutions, we are happy to advise you on the right alloy, tailored to your strength, machinability, and desired surface treatment, so that your extrusion profiles perform optimally.
| Alloy | Properties | Strength | Corrosion resistance | Applications |
|---|---|---|---|---|
|
EN AW-6060 |
Lightweight, easy to work with |
Middle |
Good |
Automotive, mechanical engineering |
|
EN AW-6061 |
High strength, wear resistant |
High |
Depending on alloy |
Heavy constructions, tools |
|
EN AW-6063 |
Corrosion resistant, wear resistant |
High |
Excellent |
Food, maritime |
|
EN AW-6082 |
Lightweight, insulating |
Variables |
Variables |
Housings, medical applications |
|
EN AW-7075 |
Good conductivity, easy to process |
Middle |
Good |
Electronics, fixtures |
At TOS, we manage the entire aluminum
extrusion process: from initial design to delivery of finished
profiles. Thanks to our experience in mold development, test extrusions, and
series production, we deliver profiles that precisely match your application. With
additional options such as CNC machining , surface treatments, and
assembly , we offer a complete production process. Below, you’ll find the steps we take to produce
your custom profiles efficiently, accurately, and on schedule .
At the start of every extrusion project, we discuss the application, volumes, budget, and lead time. This initial consultation provides a clear foundation and prevents surprises throughout the process. By thoroughly identifying the end application and technical requirements at this stage, we can optimally align the profile design and production strategy. This way, TOS lays the foundation for an efficient and reliable extrusion process.
Our engineers offer Design for Manufacturing (DFM) advice to make your profile suitable for cost-efficient production. This involves considering wall thicknesses, tolerances, cavities, and overall manufacturability. We also recommend the right alloy, such as 6000 or 7000 series aluminum, tailored to strength, corrosion resistance, and finish options. This ensures your design is not only technically feasible but also economically attractive and sustainable.
After the intake and optimization process, you’ll receive a transparent quote from TOS. This quote will detail the costs for the extrusion die and the unit price, along with an indicative lead time and terms and conditions. Thanks to our experience and international network, we can guarantee competitive prices and reliable delivery times. This gives you a clear overview of the total project costs and schedule upfront, allowing you to confidently decide on the next steps.
The die design is crucial for a successful extrusion process. At TOS, our engineers create a design that precisely matches your profile design and application. The extrusion die is then manufactured by experienced partners. This step forms the basis for both the test extrusion and series production. Thanks to our technical expertise and quality control, you can count on a die that is precisely tailored to your product.
Before serial production begins, we perform a trial extrusion (First Article Inspection – FAI). This involves producing the first profiles and thoroughly testing them for dimensions, shape, and surface quality. Any CNC machining and surface treatments are also included to assess the complete result. Following feedback, we incorporate any adjustments, after which the final specifications are recorded in a design freeze. This guarantees that serial production will precisely meet your expectations.
Once the design is approved, serial extrusion begins. We produce your profiles according to the agreed-upon drawings, tolerances, and specifications. By using reliable production lines and strict process monitoring, we guarantee consistent quality, even with larger volumes. TOS offers flexibility: from small runs for prototyping to large-scale series production for industrial applications. This means you can always count on efficient and predictable delivery.
After extrusion, profiles can be subjected to additional processing, such as milling, drilling, or tapping. Using modern CNC machines , we ensure dimensional accuracy and the right functionality, tailored to the end application of your product. Whether it’s simple holes or complex machining, we deliver profiles that are immediately usable in your production process. This is how TOS combines the advantages of extrusion with the precision of CNC machining.
A key part of the extrusion process is surface treatment. At TOS, we offer various options, such as anodizing for a wear- and corrosion-resistant layer, or powder coating for color and added protection. Other treatments, such as polishing , are also possible. This way, your product not only achieves the desired functionality but also a high-quality appearance. By managing everything under one roof, you save time and money.
Quality is paramount in every extrusion project. That’s why at TOS, we perform extensive visual and dimensional inspections of the produced profiles. If desired, we can provide certificates and documentation, such as measurement reports or material certificates. This ensures that all components meet the agreed-upon specifications and quality standards. This transparent approach gives you certainty and confidence, regardless of the complexity or volume of your project.
In addition to production and processing, TOS also assembles components into complete modules. We then arrange customer-specific packaging, export documentation, and customs clearance. If desired, we keep products in stock and deliver just-in-time to you or your customer. By combining production, processing, assembly, and logistics , we take care of the entire process for you and guarantee an efficient and reliable process.
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Yes. After the extrusion process, profiles can be easily processed using CNC techniques such as milling, drilling, and tapping. This way, the profile is fully tailored to your final product and installation options.
At TOS, we offer multiple finishes, including (hard) anodizing and powder coating for a durable and aesthetic color finish. Both treatments enhance the functionality and appearance of your profile.
TOS manages the entire process: from design and materials advice to extrusion, CNC machining, and surface treatment. Thanks to our international network, we guarantee competitive prices, short delivery times, and reliable quality. This gives you a single point of contact for a complete and high-quality end product.
