How Do Aluminum Extrusions Compare to Alternative Materials?

I once replaced a steel machine guard with aluminum extrusions and noticed immediate changes. My daily struggle with moving parts became easier when I saw the simplicity and strength of aluminum.

Aluminum extrusions offer a balance of light weight, strength, cost, and sustainability compared to steel, PVC, plastics, and composites.

Let’s take a close look at each comparison to help you choose the right material.

1. What are the performance differences between aluminum and steel extrusions?

Steel and aluminum each have strengths and weaknesses in extrusion form.

Steel extrusions are strong and rigid but heavy and prone to corrosion, while aluminum offers high strength-to-weight and excellent corrosion resistance.

Strength and Rigidity

• Steel has higher rigidity and stiffness.
• Even though 7075 aluminum has high strength, steel is still stiffer.
• Aluminum has nearly 65–70% less weight than steel for same size.

Corrosion Resistance

• Aluminum naturally forms oxide layer. Coatings like anodizing improve it.
• Steel needs paint or galvanizing to resist rust.
• In humid, coastal, or industrial air, aluminum shows better resistance.

Machinability

• Aluminum is softer. It cuts fast, needs less power, and tool wear is lower.
• Steel tools experience more wear and need slower speeds and cooling.

Cost vs Performance

• Steel material costs less per pound.
• Transport and assembly costs are higher due to weight.
• Aluminum supports lightweight design and less shipping cost.

I learned this during an equipment retrofit. The steel guard was strong but heavy and rusted quickly. The aluminum version required no repainting after two years and saved 40% on weight.

2. How do aluminum extrusions compare cost-wise to PVC or plastic?

PVC and plastic extrusions are common in windows, trim, and light frames. Their cost and properties differ from aluminum.

PVC/plastic is cheaper up-front and easy to form, but aluminum gives more strength, durability, and finish quality for longer life.

Cost Breakdown

*Prices vary by market and volume.

• PVC and ABS cost less per pound and are fast to produce.
• Aluminum costs more but offers better performance and finish.

Trade-offs

• PVC cuts and welds easily.
• But it can deform under UV, heat, or weight.
• Aluminum resists sun, keeps shape, and supports heavy loads.
• For window frames, PVC may warp; aluminum remains stable and sealable.

I once tried PVC components for an outdoor kiosk and they sagged in summer heat. Aluminum kept the frame straight and stable through seasons.

3. What are the weight advantages of aluminum extrusions over other metals?

Lightweight matters in design, shipping, and ergonomics.

Aluminum extrusions offer up to 70% weight saving compared to steel and 40% compared to copper/brass, while still keeping strong performance.

Weight Comparison

• Steel is about 3× heavier than aluminum.
• Titanium is still ~70% heavier, though stronger.
• Aluminum gives a sweet spot of light weight, strength, and cost.

Design Benefits

• Easier to handle and install.
• Lower shipping costs, especially for long profiles.
• Less load on supporting structures in buildings or machinery.

I remember installing steel frames and needing extra labor. With aluminum versions, just two people could lift them with ease.

4. How sustainable are aluminum extrusions versus composite materials?

Sustainability is now a key factor in materials selection.

Aluminum is highly sustainable due to recyclability and low waste. Composites may seem eco but often lack full-cycle recyclability.

Life-Cycle Sustainability

• Aluminum scrap fully melts and reuses at low energy cost.
• Steel recycles well too, but aluminum is lighter to transport.
• Plastic may be recycled once but often ends in landfill.
• Composites are hard to recycle. Often cut and burnt or landfilled.

Eco Benefits

• Recycled aluminum uses just 5% energy of making new.
• Recycling cuts greenhouse emissions and saves resources.
• Composites often use toxic resins and limited end-life options.

I once audited a factory and noticed aluminum scraps collected for recycling. They earned cash, and it closed the loop. No one recycles composite test parts, they just toss them.

Conclusion

Aluminum extrusions shine when you need lightweight, strong, durable, and sustainable materials. Steel is stronger but heavy and rusts. PVC/plastic is cheap but warps and wears. Composites feel high-tech but often end up as waste.

Choosing aluminum helps your project last long, stay light, and leave a smaller carbon footprint.

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