6 08, 2025

Aluminum Extrusion for Defense: Hypersonics & Satellites

2025-08-19T15:23:15+00:00August 6th, 2025|

A satellite and a dome structure against a starry background. The text reads: "Aluminum Extrusion for Defense: Hypersonics & Satellites" with a logo for Taber.

Key Takeaways

  • Aluminum extrusion is essential for next-gen defense systems like hypersonics and satellite constellations, offering strength, thermal performance, and weight reduction.
  • U.S.-based large-scale extrusion enhances national security by ensuring supply chain reliability, compliance, and fast production for military needs.
  • Advanced extrusion capabilities are critical for meeting complex defense specs across air, space, land, and sea—requiring precision, scale, and certified manufacturing.

As defense systems evolve at breakneck speed, the demand for precision-engineered components grows just as fast. Aluminum extrusion for defense is one area where innovation in materials and manufacturing meets the strategic needs of military modernization. From hypersonic weapons to satellite constellations, aluminum’s versatility, strength, and weight advantages make it a natural fit for next-generation systems.

Aluminum extrusion enables hypersonic systems, the role of aluminum profiles in satellite constellations, and the strategic value of large-scale aluminum extrusion to achieve domestic and defense manufacturing objectives. Furthermore, it highlights why OEMs and defense contractors increasingly rely on U.S.-based suppliers with robust capabilities, such as those with access to the largest direct presses in North America.

Hypersonics and the Need for Advanced Materials

Hypersonic flight, which travels at speeds exceeding Mach 5, requires components that can withstand extreme temperature gradients, aerodynamic forces, and mechanical stress. According to NASA’s overview of hypersonic systems, materials must retain structural integrity under intense conditions, particularly around leading edges and thermal management areas.

Defense contractors such as Lockheed Martin and Northrop Grumman are investing heavily in hypersonic platforms. These systems often require custom extrusions for airframe structures, enclosures, and heat sink components that must be lightweight yet incredibly durable. Well, this is precisely how aluminum extrusion supports hypersonic systems: by offering thermal efficiency, formability, and high strength-to-weight ratios tailored to specific use cases.

In addition, aluminum’s recyclability supports long-term lifecycle management. This is increasingly important as the CBO highlights a shift in defense budgets toward cost-effective and sustainable development.

Satellite Constellations and Lightweight Engineering

The aerospace shift toward satellite constellations and extensive networks of small, modular satellites has transformed how we think about orbit-based assets. Therefore, these networks require components that are compact, scalable, and resilient in harsh environments.

A recent innovation, as explored by Airforce-Technology, shows that constellations offer better redundancy, real-time data, and defense-grade surveillance. However, to make this work, manufacturers need high-strength, precision-built structures that won’t add excessive launch weight.

Why Aluminum Profiles for Satellite Constellations are Invaluable

  • Mechanical flexibility for modular designs
  • Excellent dimensional stability under orbital conditions
  • The extrusion process enables high repeatability, crucial for scalable deployment

OEMs can source custom aluminum components for military systems that reduce mass without compromising integrity. In fact, this leads to cost savings on launches and increased payload capacity.

Large-Scale Aluminum Extrusion and Strategic Capacity

Beyond performance, production scale and domestic availability are vital factors for defense logistics. Hence this is where large-scale aluminum extrusion operations come into play, especially those that can accommodate complex geometries and thicker profiles in a single piece.

In particular, aluminum extrusion for military and defense programs requires suppliers who can deliver structural consistency, high-performance alloys, and geometrical precision on a large scale, all while meeting rigorous certification standards.

Scale is about agility in meeting defense specifications, such as MIL-STD compliance and ITAR certification. Defense-focused manufacturers capable of rapid prototyping and multi-alloy extrusion processes can meet increasingly complex defense needs across air, space, land, and sea platforms.

Domestic Manufacturing and National Security

Relying on offshore suppliers for mission-critical parts introduces unacceptable risks, ranging from political instability to delayed logistics. In an era where global supply chains are under scrutiny, domestic metal processing capacity has become a cornerstone of national security.

Aluminum extrusions manufactured on U.S. soil by trusted partners enable:

  • Better quality control
  • Faster lead times
  • Closer alignment with federal defense requirements

Add to that the growing demand for OEM aluminum components that meet both technical performance and sustainability standards, and the case for reshoring aluminum manufacturing becomes clear.

Verified Compliance and U.S. Manufacturing Facilities

For procurement teams and program managers, selecting an aluminum extrusion company with verified compliance and U.S. manufacturing facilities is no longer a preference but a necessity. Few companies are as well-positioned as Taber Extrusions to meet this moment in defense manufacturing.

Taber combines vertically integrated operations and deep technical expertise with access to the largest direct extrusion presses in North America. Taber’s team of experts deliver complex, custom solutions for some of the most challenging defense applications.

This August, Taber participated in the 2025 SMD Symposium in Huntsville, Alabama, a key event for professionals in the missile defense, aerospace, and military space sectors. Maintaining strong industry relationships and actively supporting its growth are integral to Taber’s role.

A promotional banner for the 2025 Space & Missile Defense Symposium detailing the event's schedule and location in Huntsville, Alabama. It highlights industry advancements, including aluminum extrusion for defense applications, with the symposium's branding and website for further information.
Image Attribution: https://smdsymposium.org/

As a gesture to program managers and engineers evaluating new suppliers, Taber offers a free technical consultation to discuss extrusion needs, material compatibility, and project feasibility. This is a no-obligation opportunity to learn how extrusion could enhance your program’s design and efficiency before issuing your next RFP.

Contact Taber today to get started!

6 07, 2025

Custom Aluminum Extrusions: Advancing Precision Manufacturing

2025-07-23T21:54:12+00:00July 6th, 2025|

A close-up view of a custom aluminum extrusion. The text on the left reads “Custom Aluminum Extrusions: Advancing Precision Manufacturing,” with Taber’s logo at the bottom.

Key Takeaways

  • Custom aluminum extrusion delivers precision, strength, and design flexibility across high-performance industries.
  • 6000 series aluminum alloys offer excellent extrudability, corrosion resistance, and structural integrity.
  • Advances in die design, automation, and additive manufacturing enhance efficiency and product complexity.
  • Extruded aluminum supports sustainability goals through recyclability and use in renewable energy and EV applications.

Custom aluminum extrusion is the modern evolution of a centuries-old practice — shaping metal through controlled heat and pressure to meet exacting standards. What began as a rudimentary technique is now a highly precise manufacturing method that produces lightweight, durable profiles for industries like aerospace, infrastructure, and electric vehicles. From streamlined designs to structural strength, extruded aluminum plays a critical role in advancing performance across sectors.

Materials Used in Custom Aluminum Extrusion

Different industries require specific mechanical properties, such as strength, flexibility, or corrosion resistance. The 6000 series alloys — especially 6061 and 6063 — are among the most commonly used due to their excellent extrudability, structural strength, and corrosion resistance. These alloys strike a balance that makes them ideal for applications in construction, automotive aluminum components, and industrial frameworks.

Core Manufacturing Process

  • Billet Preparation

The foundation of any successful aluminum extrusion lies in precise billet preparation. Aluminum alloy billets — cut to exact specifications — serve as the starting material. These billets are carefully heated to an optimal temperature range that allows for maximum plasticity without compromising mechanical strength. This process ensures the material flows efficiently during extrusion while maintaining structural integrity.

Throughout the preparation phase, billets undergo strict quality control to detect any inconsistencies in composition or dimensions. Even slight variations can affect extrusion performance and the final product’s reliability. Maintaining uniformity at this stage sets the tone for high-quality extruded aluminum profiles.

  • Die Design and Engineering

Die configuration plays a critical role in the custom aluminum extrusion process. Today’s engineers use advanced computer-aided design (CAD) systems to develop complex die geometries while predicting material flow under pressure. Through detailed flow simulations, they can strategically position bearing surfaces and feed ports to achieve even aluminum distribution.

Thermal management is another essential factor. By integrating heat-regulating features within the die, manufacturers maintain consistent temperatures during extrusion — ensuring uniform material flow, reduced defects, and a high-quality surface finish across all extruded aluminum profiles.

A row of various metal profiles and shapes, including round, square, rectangular, and L-shaped cross-sections, is arranged. The assortment showcases different metal bars and tubes used in construction and manufacturing.

Image Attribution: Designed by Freepik. https://www.freepik.com/premium-photo/stack-rolled-metal-products-3d-rendering_146010077.htm#fromView=search&page=1&position=44&uuid=9f885ce2-2602-4f57-9cc4-371a7a879d1f&new_detail=true

Extrusion Parameters in Custom Aluminum Extrusion

Precision control over key variables is essential to custom aluminum extrusion. Ram speed, typically between 5 and 100 mm/sec, must be adjusted based on alloy type and profile complexity. Container temperatures are held within ±5°F to preserve material quality and avoid defects.

Breakthrough pressure — usually ranging from 35 to 70 MPa — must be monitored closely to maintain consistent flow. Exit temperature control is equally critical, helping prevent surface imperfections and ensuring dimensional accuracy in the final extruded aluminum product.

What Are the Benefits?

  1. Strength-to-weight ratio: Tailored aluminum extrusions provide significant strength while maintaining a lightweight profile, making them perfect for situations where minimizing weight is crucial.
  2. Corrosion resistance: The natural oxide layer on aluminum provides inherent protection against corrosion, enhancing longevity.
  3. Thermal and electrical conductivity: Aluminum’s excellent conductivity makes extruded aluminum suitable for heat dissipation and electrical applications.
  4. Recyclability and sustainability: Aluminum is 100% recyclable without loss of properties, contributing to sustainable manufacturing practices.
A graphic illustration shows the lifecycle of an aluminum billet in the extrusion process. The stages include aluminum alloy chemistry, billet casting, aluminum extrusion process, delivery, use phase, and recycling.

Precision and Excellence

Delivering high-quality custom aluminum extrusions requires rigorous inspection at every stage. Dimensional accuracy, surface finish, and compliance with industry standards are closely monitored to ensure each product meets its intended performance criteria.

Developments in Extrusion Technology

Recent technological progress has improved the functionalities of custom aluminum extrusion:

  • Friction stir welding: This technology allows the joining of extruded aluminum components without melting the base material, resulting in superior weld strength.
  • Precision extrusions: These modern methods enable tighter tolerances and complex geometries, expanding the scope of aluminum extrusion applications.
  • Automation and industry 4.0: Integration of smart technologies, including sensors and real-time monitoring, ensures higher efficiency and precision in the aluminum extrusion process.

Global Market Overview

The market for custom aluminum extrusions continues to grow, driven by demand across key industries:

  • Market size: The automotive, construction, and electronics sectors will drive the global custom aluminum extrusion market to exceed $100 billion by 2027.
  • Industry demand and trends: The growing emphasis on lightweight materials, aluminum sustainability, and custom aluminum profiles has fueled innovation and demand in the extrusion market.
  • Regional trends: Asia-Pacific regions remain the largest market, with China accounting for a substantial share due to its robust manufacturing base.

Aluminum Extrusion in Sustainability and Environmental Impact

Custom aluminum extrusions align with the global shift towards sustainable practices. The process’s recycling capabilities make it environmentally friendly, with aluminum’s infinite recyclability reducing energy consumption and environmental impact. Notably, recycled aluminum requires only 5% of the energy used in primary production. Advances in extrusion technology further enhance energy efficiency by minimizing resource use while maintaining high performance.

Additionally, extruded aluminum profiles play a critical role in renewable energy projects, serving as essential components in solar panel frames and wind turbine systems.

Emerging Innovations in Custom Aluminum Extrusion

New technologies continue to expand the possibilities for custom aluminum extrusions:

  • Electric vehicles (EVs): Lightweight aluminum profiles improve range and efficiency by forming key structural and thermal systems in EV frames and battery enclosures.
  • Modular construction: Prefabricated, extruded aluminum components speed up construction timelines while supporting sustainability goals.
  • Additive manufacturing: 3D-printed dies and tooling enable faster turnaround, design flexibility, and reduced production lead times in the aluminum extrusion process.

Taber’s Leadership in Custom Aluminum Extrusion Technology

As custom aluminum extrusion evolves, Taber Extrusions remains a proven leader in the field. With decades of experience and advanced manufacturing capabilities, Taber applies deep technical expertise to optimize extrusion performance across industries.

Their commitment to quality is evident through robust control systems and ongoing process improvements. From aerospace and defense to infrastructure and energy, Taber delivers precision-engineered extrusion solutions tailored to meet the most demanding specifications — reinforcing its position at the forefront of the industry.

A promotional graphic for Taber Extrusions highlights their capabilities in the aluminum extrusion industry. It lists their partnership with National Material L.P., their diverse services including casting, extrusion, FSW, and value-added services, and their locations in Russellville, AR, and Gulfport, MS. The industries served include military & defense, guns & archery, aircraft & aerospace, naval marine, transportation, and architectural structures. The graphic includes the tagline “The Shape of Endless Possibilities” and features an illustration of various aluminum extrusions.

Take the Next Step in Precision Manufacturing

When precision matters, custom aluminum extrusion from Taber Extrusions delivers. With decades of experience and industry-leading capabilities, Taber’s technical team offers in-depth consultations to align extrusion design with exact application requirements. From complex geometries to high-performance alloys, Taber engineers develop optimized manufacturing solutions tailored to your most demanding projects.

Ready to get started?

Contact Taber Extrusions or fill out the form below to speak with an engineer and explore custom aluminum extrusion solutions built for your success.

Request A Quote

    CONTACT INFORMATION

    YOUR PROJECT NEEDS

    Please specify extrusion alloy and length below

    If you have design files for extrusion or FSW please upload below

    Excepted file formats: jpg, pdf, png.

    Please specify FSW alloy class, welding type and panel dimensions below.

    Alloy*

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    Select Billet Size *

    6 06, 2025

    How the Largest Aluminum Direct Press and Aerospace Event Align

    2025-06-24T15:04:29+00:00June 6th, 2025|

    Eight aircraft flying in formation, emitting red, white, and blue smoke trails against a blue sky. Overlayed text “How the Largest Direct Press Aligns with the Largest Event in Aerospace” and Taber logo in lower left corner.

    Key Takeaways

    • The largest direct press in North America expands what’s possible in aerospace and defense manufacturing — enabling larger, more complex, and structurally efficient aluminum profiles.
    • Large-scale extrusion technology supports next-generation aerospace demands by reducing welds, improving design flexibility, and ensuring tight tolerances for high-performance applications.
    • Taber Extrusions is investing in the future with a 10,000-ton press, offering vertically integrated, scalable solutions for aerospace OEMs and Tier 1 suppliers who are backed by experience, certification, and innovation.

    Image Attribution: https://phototheque.siae.fr/medias/2023/presentations-en-vol/PHOTO___3534___siae2023-pdf-20230624-144827

    The largest aluminum direct press in North America is setting a new benchmark for innovation in aluminum aerospace and defense manufacturing. As extrusion capabilities scale up, the industry is witnessing a shift in what’s possible — just in time for global spotlights like the International Paris Air Show, where next-generation aerospace technologies are unveiled.

    This article explores how large-scale extrusion technology meets the complex demands of modern aerospace and defense applications. From high-strength, large-format aluminum components to sustainability goals and expanded design freedom, we’ll examine how advanced equipment is transforming what’s achievable — and how Taber is leading the charge.

    The Role of Advanced Extrusion in Aerospace and Defense

    Aluminum remains a staple material across aerospace and defense manufacturing due to its strength-to-weight ratio, corrosion resistance, and machinability. Its reliability under stress makes it essential for fuselage components and structural parts in defense vehicles. According to NASA’s aerospace materials research, aluminum alloys remain a core element of aircraft structural design because they offer an optimal balance of weight, strength, and cost-efficiency.

    As aircraft frames scale up and defense systems demand more integrated structures, the industry requires advanced aerospace extrusion solutions that can handle extreme specifications. NASA’s technical evaluation of formability in aerospace-grade aluminum highlights the importance of designing materials and processes that maintain structural integrity at scale.

    Aligning with the International Paris Air Show

    Held every two years at Le Bourget, the International Paris Air Show is the premier stage for global aerospace innovation. It’s where industry leaders, engineers, and decision-makers gather to explore the future of flight and manufacturing. The launch of Taber’s largest direct press aligns with the innovation cycle celebrated at the Paris Air Show — demonstrating how technology, scale, and timing converge to shape the next chapter of aerospace manufacturing.

    Image Attribution: https://phototheque.siae.fr/medias/2023/halls-expositions/PHOTO___3529___pavillon-us

    As aerospace OEMs and Tier 1 suppliers look to differentiate themselves through material efficiency, structural performance, and supply chain resilience, extrusion capabilities will play a key role in strategic conversations. Technologies like high-tonnage presses support sustainable aerospace development by reducing material waste and enabling lighter, stronger builds. The U.S. Department of Energy’s ShAPE™ initiative demonstrates how new aluminum processing methods can significantly reduce energy consumption in the production of high-performance aerospace materials.

    How to Choose an Aluminum Extrusion Supplier

    Sourcing aluminum extrusion for aerospace is not purely a cost decision. Key criteria include equipment capabilities, material expertise, certifications, and production scale. Can the supplier handle extensive profiles and complex specs? Are they familiar with alloys used in aerospace and defense? Do they meet industry-specific quality standards?

    The FAA’s Advisory Circular AC 43.13-1B offers detailed structural and maintenance guidance for aerospace materials, including aluminum. As innovations like the largest direct press become available, suppliers with advanced infrastructure can better support both prototyping and high-volume production — while maintaining tight tolerances and material integrity.

    Why Taber Extrusions Is Poised to Deliver

    Taber Extrusions will bring its 10,000-ton direct press online in 2026, positioning itself as a leader in high-strength aluminum extrusion for demanding industries. Designed to support aerospace and defense manufacturing, the press represents Taber’s long-term investment in innovation and sustainability.

    From casting to finishing, Taber’s vertically integrated operations offer complete control over quality, lead times, and material consistency. The enhanced capacity of the press unlocks new potential for custom aerospace profiles — meeting the increasingly complex demands of modern aircraft and defense systems.

    Image Attribution: https://phototheque.siae.fr/medias/2023/aeronefs-statique/PHOTO___3932___armee-de-lair

    Taber will also attend the International Paris Air Show from June 16–18, 2025, in Paris, France. Their presence reflects alignment with global innovation cycles and offers a valuable opportunity for OEMs, Tier 1 suppliers, and industry leaders to explore aerospace extrusion solutions directly with Taber’s technical experts.

    Let Taber Help You Source With Confidence

    Ready to meet the demands of modern aerospace and defense manufacturing? Access Taber’s entire catalog of aluminum profiles designed for complex, high-volume, and large-scale extrusion needs.

    • Engineered for aerospace and defense specifications
    • Built for strength, precision, and scalability
    • Backed by advanced extrusion technologies, including a 10,000-ton direct press

    Download their brochure or request a quote below.

    Request A Quote

      CONTACT INFORMATION

      YOUR PROJECT NEEDS

      Please specify extrusion alloy and length below

      If you have design files for extrusion or FSW please upload below

      Excepted file formats: jpg, pdf, png.

      Please specify FSW alloy class, welding type and panel dimensions below.

      Alloy*

      Welding Type*

      Select Billet Size *

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      19 05, 2025

      In Focus Spotlight: Tony Amendola, National Accounts Manager

      2025-05-28T20:25:55+00:00May 19th, 2025|

      Image of Taber's In Focus Spotlight, Tony Amendola, smiling with his wife.

      With over three decades of experience in the aluminum extrusion industry, Tony Amendola brings a wealth of knowledge and strategic insight to his role as National Accounts Manager – OEM at Taber Extrusions. Tasked with managing the company’s national account base and aligning new prospects with Taber’s upcoming press expansion in 2026, Tony plays a key role in shaping the future of our customer relationships and business growth. Prior to joining Taber, Tony spent 31 years specializing in value-added applications and specialty sales, giving him a strong foundation to help accelerate growth opportunities. He’s passionate about fostering an inclusive, collaborative culture across departments—leveraging his leadership experience to drive success and unity within the organization.

      When you’re not at work, what can we find you doing?

      Traveling with my family, golfing for leisure, landscaping projects, and volunteering for local underprivileged youth.

      Hometown?

      I was born in Boardman, OH (Northeast Ohio).

      Family? Children?

      I’m married to my wife Jennifer and we have two kids, Carly and Anthony.

      Favorite part about working for Taber so far?

      The team is all moving in one common direction, regardless of department or title.

      A photo of In Focus Spotlight Tony Amendola's two kids, a daughter and son, smiling at a formal dinner table.

      What sets Taber apart from other companies that deliver the exact same things?

      Taber knows who they are in terms of what products and processes are a fit which results in less wasted motion and overall energy.

      Taber is growing rapidly. Any advice for those looking to join the Taber team?

      The upcoming expansion and company growth plans are massive. There will be opportunities in all areas of the company and a significant career growth path for those wanting to join the industry.

      What do you think the future holds for Taber?

      The future is very bright; Taber has not only invested in new equipment and capability, but has also added a high degree of quality in terms of its’ people and specialty personnel needs.

      Is there anything we didn’t bring up you’d like to talk about?

      Taber has the unique position of being a major player in both the regional Southeastern U.S. market, as well as in the national/international arena. Our variety of profile sizes and alloy options set us apart from your “typical” aluminum extrusion sources; there is no other North American source that covers such a footprint.

      Learn about other team members of Taber Extrusions through our In Focus Spotlight.

      Interested in becoming a part of the Taber Team? Submit your resume to careers@taberextrusions.com.

      More About Taber

      In 1995, Taber expanded its capabilities with the acquisition of a state-of-the-art extrusion facility in Gulfport, MS. This advanced operation features a modern cast house, high-performance extrusion presses, microextrusion technology, and enhanced fabrication capabilities—positioning Taber to serve a wide range of industries with greater precision and efficiency.

      From aerospace and automotive to marine, infrastructure, sporting goods, and military applications, Taber delivers high-quality soft and hard alloy cast and extruded products tailored to meet diverse market needs.

      As an industry pioneer, Taber also leads in friction stir welding (FSW), offering fully integrated solutions that include aluminum extrusion, precision machining, and raw material supply. As one of the few North American providers of FSW panels and assemblies, Taber sets the standard for innovation in advanced aluminum manufacturing.

      Become a customer today! Visit us, request a quote or call us at (888) 985-5319.

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      6 05, 2025

      Aluminum Extrusion for Drones: An Expanding Industry

      2025-06-16T13:56:31+00:00May 6th, 2025|

      An illustration depicts a drone flying over a mountainous landscape during sunset, with the text “Aluminum Extrusion for Drones: An Expanding Industry” prominently featured. The “TABER” logo is positioned at the bottom.

      Key Takeaways:

      • Aluminum extrusion for drones supports lightweight strength, thermal management, and modular design — critical features for modern UAV functionality.
      • Aerospace aluminum extrusions are essential for constructing UAV airframes, payload bays, and heat dissipation components, especially in larger, mission-adaptable drones.
      • Taber Extrusions is advancing aerospace innovation with one of the largest direct presses in North America, offering precision-engineered solutions for UAVs, satellites, and defense systems.

      The unmanned aerial vehicle (UAV) industry is evolving rapidly, with drones now playing a major part in surveillance, logistics, agriculture, and defense. As these applications expand, so does the need for high-performance materials that can enhance efficiency, endurance, and sustainability. Aluminum extrusion for drones is developing as a momentous solution, offering the strength, lightweight aluminum aerospace properties, and versatility required for modern autonomous aircraft designs.

      Whether for small drones used in aerial photography or large automated flying devices deployed in military and commercial operations, aerospace aluminum extrusions are transforming the industry.

      This article explores the fundamental applications of aluminum extrusions in aerial vehicle manufacturing, their impact on component fabrication, and how advancements in extrusion solutions for drone manufacturing are forming the future of aerospace and defense.

      Aluminum Extrusions in UAV Development

      Aluminum’s unique properties make it a go-to material for aerial system construction. Its lightweight nature contributes to extended flight time and improved fuel efficiency, while its inherent strength maintains structural integrity under intense operational demands.

      Aluminum extrusion manufacturers utilize precision processes to produce complex, custom profiles that meet the specialized requirements of UAV design. This level of customization is critical for drone performance and modularity.

      In addition to strength and weight advantages, aluminum offers natural corrosion resistance — ideal for drones exposed to a range of environments. Its high thermal conductivity also supports heat dissipation from motors and onboard electronics. These characteristics make aluminum extrusions essential in building UAV frames and housings that are durable, serviceable, and scalable for future upgrades.

      Studies have also highlighted the role of aluminum in reducing UAV weight, which directly enhances flight range and efficiency. ResearchGate emphasizes that lightweight materials like aluminum are critical for UAVs to resist aerodynamic loads while maintaining extended operational periods. Furthermore, advancements in extrusion techniques allow for the production of intricate profiles, enabling UAV manufacturers to meet stringent design and performance criteria.

      A CNC lathe machine demonstrates the precision shaping of an aluminum extrusion for drones, with a rotating chuck holding the workpiece and a cutting tool in action. The setup highlights advanced manufacturing processes in aerospace technology.

      Key Applications of Aluminum Extrusions in Unmanned Aerial Vehicles

      • Structural frames & airframes

      Lightweight aluminum aerospace materials provide aerial platform structures with the necessary strength and durability while minimizing weight. Extruded aluminum components allow for streamlined designs that improve aerodynamics and reduce fuel consumption.

      • Heat dissipation components

      High-performance autonomous aircraft generate heat from batteries, motors, and electronic systems. Aluminum’s outstanding thermal conductivity makes it perfect for heat sinks and cooling plates, helping to prevent overheating and ensuring system longevity.

      • Landing gear & support structures

      This technology’s landing gear must withstand significant impact forces while remaining lightweight. Aluminum extrusions combine durability and adaptability, guaranteeing a sturdy support framework capable of withstanding multiple landings.

      • Modular payload bays

      Advanced aluminum extrusion for drones allows manufacturers to create modular payload bays, enabling remote-controlled aircraft to adapt for various missions such as surveillance, cargo transport, and aerial mapping. This modularity is essential for commercial and defense applications where mission profiles change frequently.

      The Role of Aluminum in Aerospace and Defense

      Aluminum extrusions, including unmanned combat aerial vehicles (UCAVs), are key in aerospace and defense applications. These UAVs demand high-strength, lightweight materials for maximum efficiency, endurance, and mission adaptability. Aluminum extrusion manufacturers supply precision-engineered components designed to withstand extreme operational conditions while maintaining optimal performance.

      Advancements in Unmanned Aerial Vehicles and Aerospace Aluminum Extrusion Technology

      • Improved Alloy Composition

      New aluminum alloys enhance durability, corrosion resistance, and weight reduction, vital for this technology’s operation in extreme environments.

      • Precision Engineering

      Extrusion solutions for drone manufacturing now include tighter tolerances and complex geometries, improving aerodynamic efficiency.

      • Sustainability

      As industries push for greener manufacturing, recyclable aluminum extrusions reduce carbon footprints in aerospace and UAV production.

      Expanding Beyond UAVs

      The benefits of aluminum extrusion for drones extend to the broader aerospace industry, including satellites and spacecraft. The ability to create large, seamless aluminum components supports spacecraft structural frames, satellite panels, and aerospace-grade heat dissipation systems.

      An illustration categorizes aluminum profiles into non-standard and standard types, showcasing their diverse applications. This highlights the versatility of aluminum extrusions for drones, emphasizing their adaptability to various structural and functional needs.

      Pioneering Aluminum Solutions for Aerospace

      As the demand for high-performance aluminum extrusions continues to rise, Taber Extrusions is leading the innovation charge. Their upcoming 10,000-ton press, scheduled to launch in 2026, marks a significant leap forward in UAV and aerospace manufacturing capabilities. Designed with a 16-inch container, this state-of-the-art press will be one of the largest direct extrusion presses in North America, capable of producing larger, more complex profiles with unmatched precision.

      Engineered to meet the rigorous demands of the aerospace, defense, and heavy industrial markets, this press reflects Taber’s commitment to innovation, scale, and long-term performance.

      Advanced Technology for Advanced Aerospace Needs

      The new press features a pre-stressed press frame with laminated tie-rods, ensuring stability and accuracy under high-force operations. It’s also equipped with cutting-edge technology like the IAS Induction Heater for billet taper and a multi-spray zone profile quench, enhancing both the quality and consistency of extrusions.

      These innovations empower Taber to process both hard and soft aluminum alloys, offering enhanced versatility for aerospace applications — from automated flying systems to satellites.

      Taber’s dedication to quality, precision engineering, and evolving material science reinforces its position as a trusted partner in aerospace innovation. As drone and aerospace technologies continue to advance — and integrate further into national airspace — Taber remains aligned with evolving industry standards, including those outlined by the Federal Aviation Administration (FAA).

      Optimize Your Aerial System Performance with Precision Aluminum Extrusions

      Industry leaders rely on aerospace-grade aluminum extrusions for unmatched strength, weight savings, and durability in UAVs, satellites, and defense systems.

      Download Taber Extrusions’ capabilities brochure to explore cutting-edge extrusion solutions for UAV component fabrication and aerospace innovation.

      You can also fill out the form below, and discover how Taber Extrusions can elevate your projects today!

      Request A Quote

        CONTACT INFORMATION

        YOUR PROJECT NEEDS

        Please specify extrusion alloy and length below

        If you have design files for extrusion or FSW please upload below

        Excepted file formats: jpg, pdf, png.

        Please specify FSW alloy class, welding type and panel dimensions below.

        Alloy*

        Welding Type*

        Select Billet Size *

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        6 04, 2025

        How Advanced Aluminum Fabrication is Shaping the Future

        2025-06-16T13:11:51+00:00April 6th, 2025|

        An illustration features a light bulb with various icons inside, including a factory, a circuit board, and an airplane, symbolizing different industries. The text reads, “How Advanced Aluminum Fabrication is Shaping the Future.”

        Key Takeaways:

        • Advanced aluminum fabrication, including CNC machining and friction-stir welding, enhances strength, durability, and fuel efficiency in aerospace applications.
        • Innovative aluminum fabrication techniques are transforming how aluminum is used in high-tech industries, ensuring precision and cost-effectiveness.
        • As industries demand lighter, stronger, and more sustainable materials, aluminum fabrication techniques will continue to reshape aerospace, automotive, and defense manufacturing.
        • Taber Extrusions continues to advance aluminum fabrication for the future of aerospace, automotive, and defense.

        Advanced aluminum fabrication is a driving force behind innovation in industries where precision, performance, and efficiency are non-negotiable. From aerospace engineering to automotive design and defense applications, aluminum’s lightweight strength, durability, and infinite recyclability make it an indispensable material. Yet, what truly sets aluminum apart is the cutting-edge fabrication techniques that push its potential even further. Technologies such as friction-stir welding, CNC machining, and advanced extrusion presses are revolutionizing aluminum’s role in high-value sectors.

        This article explores how these advancements are shaping the future of aluminum fabrication, driving innovation in aerospace, automotive, and defense industries. For engineers, purchasing agents, and OEM stakeholders, keeping up with these developments isn’t just about staying informed — it’s about making strategic decisions that align with evolving industry demands.

        Aluminum Fabrication in Aerospace: Precision Meets Performance

        When it comes to aerospace applications, there’s no margin for error. Every component must meet exacting tolerances, withstand extreme conditions, and contribute to overall weight reduction, a factor critical for fuel efficiency. Advanced aluminum fabrication has become a cornerstone of aerospace manufacturing thanks to its ability to combine strength, durability, and lightness.

        One of the most significant advancements in recent years is precision aluminum machining. This computer-controlled process allows manufacturers to create complex geometries with micron-level accuracy. For instance, aircraft frames and engine components often require intricate designs that traditional methods cannot achieve. By leveraging CNC technology, fabricators can produce these parts faster and more reliably than ever before.

        Another breakthrough technique is friction-stir welding, which eliminates many drawbacks of conventional welding. Unlike traditional fusion welding, friction stir welding uses mechanical pressure and heat generated by rotating tools to join aluminum alloys. The result? Stronger bonds with minimal distortion are a game-changer for aerospace engineers who demand flawless joints in structural components.

        Beyond functionality, aerospace-grade aluminum solutions also prioritize sustainability. Aluminum is 100% recyclable without losing its core properties, making it a sustainable choice for an industry facing growing pressure to reduce carbon emissions. In fact, nearly 75% of all aluminum produced since 1888 is still in use today — a testament to its longevity and environmental benefits.

        A satellite in space with the text “Taber Does That? Journey Through Space with Us.” The image promotes Taber Extrusions’ aerospace aluminum, highlighting its role in satellite construction for reliability and performance beyond Earth’s atmosphere. The Taber Extrusions logo and website URL are displayed at the bottom.

        Custom Aluminum Fabrication for Automotive Innovation

        The automotive industry is evolving rapidly, driven by electrification, autonomous technologies, and stringent emissions regulations. As manufacturers seek to develop lighter, safer, and more efficient vehicles, advanced aluminum fabrication has become essential in achieving these goals.

        One standout application is the development of micro-extrusion capabilities, which enable the production of ultra-thin profiles and small-diameter tubes. These components are essential for cooling systems, battery enclosures, and sensor housings in electric vehicles (EVs). Micro-extrusions not only enhance thermal management but also improve energy efficiency, a crucial consideration for EV manufacturers aiming to extend range and reduce charging times.

        Beyond micro-extrusions, custom aluminum extrusion for automotive offers endless possibilities for design flexibility. Manufacturers can create bespoke shapes and sizes tailored to specific vehicle models, ensuring optimal fit and function. Because of their excellent strength-to-weight ratio, manufacturers commonly use aluminum extruded parts in chassis construction, door frames, and roof rails.

        Moreover, the integration of advanced CNC machining ensures that even the most intricate automotive components meet rigorous quality standards. Whether crafting precise mounting brackets or machining detailed surface finishes, CNC technology guarantees consistency and reliability across large-scale production runs.

        As sustainability continues to shape consumer preferences, automakers are turning to aluminum not only for its performance advantages but also for its recyclability. According to S&P Global Commodity Insights, recycling aluminum requires just 5% of the energy needed to produce primary aluminum. This makes aluminum fabrication a win-win for both manufacturers and the planet.

        Military & Defense Applications of Aluminum Fabrication

        Advanced aluminum fabrication plays a critical role in modern defense manufacturing, offering high-strength, lightweight solutions that enhance durability and performance in demanding environments.

        One notable advancement is the use of large-scale aluminum extrusion capabilities to manufacture structural components for military hardware. For example, manufacturers widely use aluminum extrusions in the frames of troop carriers, missile launchers, and radar systems. Their ability to absorb impact while maintaining structural integrity is invaluable in combat scenarios.

        : A military aircraft parked on an airstrip with the text “Military & Defense Applications of Aluminum Fabrication.”

         

        Friction-stir welding has also found widespread adoption in defense manufacturing. This technique enables the creation of seamless, high-strength joints in armor plating and other protective structures. Compared to traditional welding, friction-stir welding reduces material waste and enhances durability, a critical factor for equipment operating in harsh environments.

        Another growth area is the development of custom aluminum fabrication for defense electronics. Lightweight yet robust enclosures house sensitive instruments, ensuring they remain operational under extreme conditions. These enclosures often incorporate advanced CNC machining to achieve tight tolerances and smooth finishes, enhancing performance.

        Defense contractors increasingly prioritize sustainability alongside functionality. Recycled aluminum meets stringent military specifications while reducing reliance on virgin materials. This dual focus on performance and eco-friendliness underscores aluminum’s enduring appeal in defense applications.

        The Future of Aluminum Fabrication: Innovation & Sustainability

        Looking ahead, the future of aluminum fabrication lies in continued innovation and a commitment to sustainability. Artificial intelligence (AI) and automation are technological advancements set to transform manufacturing processes by enabling enhanced precision and efficiency. Meanwhile, the push for greener practices will drive demand for recycled aluminum and energy-efficient fabrication techniques.

        This infographic showcases Taber Extrusions’ advanced aluminum fabrication capabilities, including CNC machining and precision cutting and sawing. Key features such as 3-axis

        Taber Extrusions exemplifies this forward-thinking approach. With investments in state-of-the-art presses, friction-stir welding, and expanded machining capabilities, Taber is well-positioned to meet the evolving needs of high-value industries. Their commitment to excellence and creativity guarantees that clients receive top-notch products crafted to surpass expectations.

        Before exploring potential partnerships, download Taber’s free corporate brochure here to learn more about their comprehensive capabilities and industry expertise. Source precision-fabricated aluminum instead of raw materials to reduce waste and machining costs, with the bonus of supply chain reliability! Partner with Taber Extrusions for your next aluminum fabrication project.

        Fill out the form below, and discover how Taber Extrusions can elevate your projects today!

        Request A Quote

          CONTACT INFORMATION

          YOUR PROJECT NEEDS

          Please specify extrusion alloy and length below

          If you have design files for extrusion or FSW please upload below

          Excepted file formats: jpg, pdf, png.

          Please specify FSW alloy class, welding type and panel dimensions below.

          Alloy*

          Welding Type*

          Select Billet Size *

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          6 03, 2025

          The Backbone of Heavy Industry: Aluminum Extrusion

          2025-06-16T14:04:52+00:00March 6th, 2025|

          A promotional graphic features several brightly colored excavator arms against a clear blue sky, with the text “The Backbone of Heavy Industry: Aluminum Extrusion” prominently displayed. The logo for “TABER” is also included below the text.

          Key Takeaways:

          • Heavy industry aluminum extrusion is essential for construction, transportation, energy, and manufacturing, offering durability, lightweight strength, and design flexibility.

          • Challenges like rising costs, global competition, and supply chain disruptions can be mitigated by partnering with an experienced aluminum extrusion manufacturer.

          • Taber Extrusions provides cutting-edge CNC machining, large press capabilities, and sustainable manufacturing solutions, ensuring high-quality, customized aluminum extrusion for heavy industry.

          Heavy industry is the foundation of modern economies, encompassing sectors such as construction, energy, transportation, and manufacturing. The materials and processes powering this sector must meet stringent demands for strength, versatility, and sustainability. Among these, heavy industry aluminum extrusion has emerged as an indispensable technology.

          Through precision CNC machining and advanced large press aluminum extrusion techniques, manufacturers produce structural components that drive innovation across infrastructure, transportation, and energy sectors. In infrastructure, aluminum extrusions support bridges, skyscrapers, and large-scale construction projects. In transportation, they enhance efficiency and durability in automotive, rail, and aerospace applications. The energy sector relies on aluminum extrusion profiles for solar panel frames, wind turbines, and power distribution systems.

          The Markets Driving Heavy Industry

          Heavy industry comprises a variety of markets, each with unique demands and opportunities. Major sectors include:

          Construction and infrastructure:

          This sector relies on durable materials for roads, bridges, tunnels, and high-rise buildings. Heavy industry aluminum extrusion is essential for lightweight, corrosion-resistant components that ensure long-term durability. Additionally, the rise of modular construction has increased demand for prefabricated aluminum parts, reducing construction time and material waste.

          A collage featuring four scenes: a prefabricated building being assembled, a close-up of a bridge’s underside, a vast field of solar panels, and an electric car charging at a station. These elements highlight advancements in construction, infrastructure, renewable energy, and electric vehicles, which are relevant to heavy industry aluminum extrusion.

          Transportation:

          The transportation sector encompasses the automotive, aerospace, shipping, and rail industries. Aluminum extrusion is critical for reducing vehicle weight, improving fuel efficiency, and enhancing performance in transportation. For instance, businesses use aluminum profiles in electric vehicle battery enclosures, train car frames, and airplane fuselages.

          Energy:

          The renewable energy sector increasingly depends on heavy industry aluminum extrusion to manufacture critical components for solar, wind, and energy transmission systems. Applications include:

          • Solar panel frames: providing structural support and weather resistance
          • Wind turbine nacelles and support structures: ensuring strength and efficiency
          • Energy transmission components: utilizing aluminum’s lightweight conductivity for efficient power distribution

          Manufacturing and machinery:

          Heavy equipment for construction and mining depends on robust aluminum extrusions. Large press capabilities allow for the creation of massive and complex profiles tailored to machinery needs, improving both performance and durability.

          Challenges Facing Heavy Industry

          Despite its importance, heavy industry is not without its difficulties.

          • Rising costs: Energy prices, labor shortages, and material costs are squeezing profit margins. Heavy industry aluminum extrusion offers a cost-effective solution due to its efficiency and recyclability.
          • Sustainability demands: The push for greener practices means industries must reduce carbon footprints. Aluminum’s high recyclability makes it a preferred choice for sustainable manufacturing.
          • Global competition: Maintaining competitiveness requires constant innovation. Companies that adopt advanced technologies like CNC machining and state-of-the-art extrusion presses stay ahead by delivering higher-quality products.
          • Supply chain disruptions: Global events can affect material availability and lead times. Partnering with a trusted heavy industry aluminum extrusion manufacturer ensures reliable supply chains and consistent production.

          Emerging Markets and Growth Projections

          Several heavy industry markets will experience significant growth in the coming years.

          A graphic that projects the global market size for construction equipment, estimating growth from USD 161.45 billion in 2024 to USD 271.30 billion by 2032, with a 6.7% CAGR. This is crucial for companies in the heavy industry of aluminum extrusion to understand market trends and opportunities.

          These projections indicate robust growth driven by urbanization, infrastructure development, and technological advancements.

          Innovations and Advantages Supporting Heavy Industry

          Heavy industry aluminum extrusion continues to evolve, offering solutions that address the sector’s biggest challenges.

          • Strength-to-weight ratio: Aluminum provides excellent structural strength while being significantly lighter than steel, reducing transportation costs and improving efficiency.
          • Design flexibility: The aluminum extrusion process allows for intricate shapes and complex geometries, creating tailored solutions for diverse applications.
          • Durability and corrosion resistance: Aluminum’s natural rust resistance makes it ideal for outdoor and high-stress environments.
          • Precision manufacturing: Advanced techniques ensure tight tolerances and consistent quality, essential for aerospace and automotive applications.
          • Large press capabilities: Innovations in large press aluminum extrusion allow for oversized components, meeting the needs of industries like energy, infrastructure, and transportation.
          • Sustainability: Aluminum is 100% recyclable without losing its properties, making it a cornerstone of the circular economy.

          Partner with a Leading Aluminum Extrusion Manufacturer

          A worker operates a large VF-12 CNC machine in a heavy industry aluminum extrusion facility. The VF-12 logo is visible on the machine, indicating its model.To fully leverage the benefits of heavy industry aluminum extrusion, businesses must collaborate with a trusted, high-quality manufacturer.

          Taber Extrusions, a premier aluminum extrusion manufacturer in the United States, is equipped with state-of-the-art large presses, precision CNC machining, and a strong commitment to sustainability. Our advanced capabilities ensure that clients receive durable, efficient, and customized aluminum extrusion solutions that meet the rigorous demands of heavy industry.

          Unlock the Potential of Heavy Industry Aluminum Extrusion

          Learn more about the impact of aluminum extrusion on heavy industry. Download our detailed guide to extrusion innovation and applications.

          💡 Gain insights into:

          • Cutting-edge aluminum extrusion technologies
          • Industry-specific applications for construction, transportation, and energy
          • The latest trends driving heavy industry advancements

          Ready to elevate your projects with top-tier aluminum extrusion solutions?

          Fill out the form below or call us today at (800) 563-6853, and see how our capabilities can drive your success.

          Request A Quote

            CONTACT INFORMATION

            YOUR PROJECT NEEDS

            Please specify extrusion alloy and length below

            If you have design files for extrusion or FSW please upload below

            Excepted file formats: jpg, pdf, png.

            Please specify FSW alloy class, welding type and panel dimensions below.

            Alloy*

            Welding Type*

            Select Billet Size *

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            19 02, 2025

            In Focus Spotlight: Canyon Dulli, Technical Sales Specialist

            2025-02-19T15:57:14+00:00February 19th, 2025|

            A headshot of Taber's In Focus Spotlight, Canyon Dulli, from when he was in the US Navy.

            Meet Canyon Dulli, Technical Sales Specialist at Taber Extrusions. With a strong background in quality assurance and a passion for problem-solving, Canyon plays a key role in supporting both Inside Sales Representatives and Regional Sales Managers by providing expert technical guidance. As a primary point of contact for new customers, he helps develop innovative projects and ensures seamless collaboration. Before transitioning to sales, Canyon spent 5 ½ years in Taber’s Quality Department, honing his expertise in aluminum extrusion. Prior to his career at Taber, he proudly served in the United States Navy for six years as a Cryptologic Technician and Cyberspace Analyst, achieving the rank of Petty Officer Second Class (E-5). We thank Canyon for his service and for bringing his dedication, discipline, and technical acumen to the Taber team!

            What do you hope to bring to Taber in terms of leadership and company culture?

            I hope to bring a positive, friendly, and helpful attitude to the entire Taber team. I hope to lead from the front and be someone that can be relied upon.

            Hometown?

            I was born in Russellville, graduated from Dardanelle. Apart from my time stationed in Pensacola with the Navy, I’ve lived in the Russellville/Dardanelle area for my whole life.

            Family? Children?

            I’m married and have 2 children. My wife, Jacilynn, works in Occupational Therapy supporting the local elementary schools and daycares. I have an 8-year-old daughter, Gemma, currently in 2nd Grade and a 5-year-old son, Beckett, currently in Kindergarten.

            When you’re not at work, what would we find you doing?

            When I’m not at work, I’m spending time with my family and friends. I love sports and keep up with all things related to the Razorbacks and the Dallas Cowboys.

            A photo of Canyon Dulli smiling with his wife and children.
            A photo of Canyon Dulli's daughter and son smiling on a hike with their dog.

            Favorite part about working for Taber so far?

            My favorite thing about working at Taber is the people that I’ve met and the friendships that I’ve made.

            What sets Taber apart from other companies that deliver the exact same things?

            What sets Taber apart from others is our full scope of capabilities. Having the ability to provide such a wide range of different products across Extrusion, Fabrication, and Friction Stir Welding all at one facility.

            Taber is growing rapidly. Any advice for those looking to join the Taber team?

            At Taber, there’s a role for just about anyone to succeed in and now is the perfect time to join the team.

            What do you think the future holds for Taber?

            I think the future holds potential for outstanding growth, and the opportunity to set ourselves apart as one of the most capable and successful Aluminum Extrusion companies in the game. It’s up to our team to make it happen.
            Learn about other team members of Taber Extrusions through our In Focus Spotlight.

            Interested in becoming a part of the Taber Team? Submit your resume to careers@taberextrusions.com.

            More About Taber

            Since 1973, Taber Extrusions has been at the forefront of aluminum extrusion innovation, introducing the industry to rectangular billet extrusion. This breakthrough enables the production of solid profiles up to 31 inches wide and hollow profiles up to 29 inches wide, pushing the boundaries of what’s possible in aluminum manufacturing.

            Taber strengthened its capabilities in 1995 with the acquisition of a cutting-edge extrusion facility in Gulfport, MS. Equipped with a modern cast house, high-performance extrusion presses, advanced microextrusion technology, and expanded fabrication capabilities, this facility enhances Taber’s ability to serve a broad spectrum of industries.

            From aerospace and automotive to marine, infrastructure, sporting goods, and military applications, Taber delivers both soft and hard alloy cast and extruded products designed to meet diverse market demands.

            Additionally, Taber is a pioneer in friction stir welding (FSW), providing fully integrated solutions that encompass aluminum extrusion, precision machining, and raw material supply. As one of the few North American suppliers of FSW panels and assemblies, Taber continues to lead the way in advanced aluminum manufacturing.

             

            Become a customer today! Visit us, request a quote or call us at (888) 985-5319.

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            6 02, 2025

            Why Engineers Prefer Aluminum Extrusion

            2025-06-16T13:16:39+00:00February 6th, 2025|

            Two engineers wearing safety helmets and reflective vests pointing at a construction site, with the text “Why Engineers Prefer Aluminum Extrusion” and the Taber logo displayed.

            Key Takeaways

            • Engineers prefer aluminum extrusion for precision and sustainability: Aluminum extrusion processes reduce waste, offer diverse material options, and deliver corrosion-resistant, durable solutions that align with global sustainability goals.
            • Taber Extrusions offers tailored expertise: With decades of experience, Taber delivers innovative, high-quality solutions for industries, ensuring reliability and precision in every application.
            • Sustainability and innovation set Taber apart: Taber’s environment-friendly practices, advanced manufacturing processes, and ability to handle complex designs make it a trusted partner for engineers seeking excellence in aluminum extrusion.

            Why do engineers prefer aluminum extrusion? Its unmatched versatility, cost efficiency, and sustainability make it an indispensable material across industries. Aluminum extrusion has become a cornerstone in modern manufacturing and design, offering the flexibility and performance engineers need to develop innovative, reliable solutions for applications ranging from transportation to renewable energy.

            The benefits of aluminum extrusion are vast, from its adaptability to its eco-friendly properties. Engineers prefer aluminum extrusion not only for its ability to meet stringent design requirements but also for its contributions to reducing environmental impact. This blog explores why engineers consistently choose aluminum extrusions, exploring key advantages, applications, and insights across multiple industries.

            Reasons Why Engineers Prefer Aluminum Extrusion

            Aluminum extrusion provides several compelling advantages, making it the preferred material for engineers:

            1. Design versatility and precision

            Extruded aluminum can be shaped into complex profiles with tight tolerances, enabling engineers to design custom solutions tailored to specific needs. Whether it is lightweight frames for automotive applications or intricate components for aerospace, aluminum extrusion supports creativity without compromising structural integrity.

            1. Lightweight yet strong

            Aluminum alloys offer an exceptional strength-to-weight ratio, a crucial benefit in industries like transportation, aerospace, and defense, where reducing weight improves efficiency and performance. Advanced high-strength steels (AHSS) may have their applications, but aluminum extrusions provide a comparable lightweight alternative with added design flexibility. The Aluminum Extruders Council highlights how this combination of strength and weight is an industry game-changer.

            1. Aluminum extrusion in sustainability

            As industries shift toward greener practices, aluminum extrusion plays a pivotal role in sustainable manufacturing. Aluminum is 100% recyclable without losing its inherent properties, making it a sustainable choice for infrastructure, renewable energy, and automotive sectors. Engineers favor aluminum for its ability to align with long-term environmental goals, as outlined in the Aluminum Extruders Council’s guide on aluminum sustainability.

            Aluminum Extrusion Applications Across Industries

            The versatility of aluminum extrusions has secured their role in numerous industries, making it clear why engineers prefer aluminum extrusion. Let’s explore some of its key applications:

            1. Transportation

            Automotive aluminum plays a pivotal role in reducing vehicle weight, improving fuel efficiency, and meeting strict emissions standards. From crash management systems to battery enclosures in electric vehicles, extruded aluminum components are becoming essential in modern transportation.

            1. Aerospace and defense

            Lightweight aluminum alloys are critical in aerospace and defense applications, where every gram counts. Aluminum extrusion profiles contribute to robust yet lightweight aircraft, satellites, and military vehicle structures.

            1. Construction and architecture

            In construction, aluminum extrusion provides durable and aesthetically pleasing solutions. Aluminum for infrastructure includes window frames, curtain walls, and structural supports that combine strength and corrosion resistance, ensuring long-term performance.

            1. Consumer goods and electronics

            Manufacturers widely use extruded aluminum in consumer goods due to its sleek appearance, lightweight nature, and excellent thermal conductivity. It’s also a preferred material for components such as heat sinks and enclosures in the electronics industry.

            1. Renewable energy

            In renewable energy, aluminum extrusion is essential for solar panel frames, wind turbine components, and energy-efficient building designs. Engineers appreciate aluminum’s durability and resistance to environmental factors in these demanding applications. Learn more about the role of aluminum in renewable energy here.

            Why Engineers Choose Aluminum Extrusion

            Engineers prefer aluminum extrusion for its ability to deliver precision, performance, and sustainability. Its advantages include:

            • Efficient manufacturing: Extrusion processes are cost-effective, allowing for reduced material waste and streamlined production.
            • Wide material options: Aluminum alloys offer diverse mechanical properties, ensuring engineers can select the right material for the job.
            • Durability: Aluminum extrusion profiles withstand harsh environments, offering corrosion resistance and longevity.
            • Sustainability standards: Using recycled aluminum reduces energy consumption and greenhouse gas emissions, supporting global sustainability goals.
            A person wearing a checkered shirt and overalls is handling a piece of metal. Stacks of metal beams with U-shaped cross-sections are in the foreground. The setting appears to be an industrial or construction site with buildings in the background. The worker seems to be inspecting or measuring the metal beams, indicating a task related to construction or metalwork.

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            Your Trusted Aluminum Extrusion Partner

            When it comes to meeting engineers’ unique needs, Taber Extrusions stands out as a leader in the industry. With decades of expertise, Taber offers comprehensive solutions tailored to the most demanding applications. Taber’s aluminum extrusion capabilities ensure precision, quality, and reliability from transportation to renewable energy.

            Why Choose Taber?

            • Innovative solutions: Advanced manufacturing processes to meet complex design requirements
            • Commitment to sustainability: Adherence to eco-friendly practices and sustainability standards
            • Industry expertise: Proven track record serving diverse sectors, including aerospace, defense, and automotive

            Engineers trust Taber Extrusions for their commitment to excellence and ability to deliver aluminum extrusion solutions that drive success. Request a quote today to discuss how their aluminum extrusion expertise can support your next project.

            About Taber Extrusion

            For over four decades, Taber Extrusions has been at the forefront of the aluminum extrusion industry, renowned for its innovative solutions and unwavering commitment to quality. Their extensive capabilities, including the production of complex and wide profiles, set them apart as a leader in the field. Serving diverse sectors such as aerospace, defense, automotive, and renewable energy, Taber consistently delivers precision-engineered products that meet the highest industry standards. Their dedication to sustainability and customer satisfaction underscores their role as a trusted partner in engineering excellence.

            Fill out the form below, and discover how Taber Extrusions can elevate your projects today!

            Request A Quote

              CONTACT INFORMATION

              YOUR PROJECT NEEDS

              Please specify extrusion alloy and length below

              If you have design files for extrusion or FSW please upload below

              Excepted file formats: jpg, pdf, png.

              Please specify FSW alloy class, welding type and panel dimensions below.

              Alloy*

              Welding Type*

              Select Billet Size *

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              6 01, 2025

              Not Just a New Year’s Resolution: Aluminum Extrusion Sustainability

              2025-06-16T14:08:22+00:00January 6th, 2025|

              Solar panels amongst greenery and trees with a city scape background. Taber’s logo and white text “Not Just a New Year’s Resolution: Aluminum Extrusion Sustainability” overlays the image.

              Is the concept of aluminum extrusion sustainability more than just a popular industry term? With the increasing emphasis on sustainability in global markets, the significance of aluminum extrusion in promoting sustainable practices has never been greater. This extends beyond just meeting environmental standards. It involves transforming how products are made, how resources are managed, and how industries adapt to the evolving demands for greener solutions. From automotive to renewable energy, construction, and more, aluminum extrusion offers a pathway to reducing carbon footprints and advancing sustainable development.

              This blog explores how aluminum extrusion contributes to sustainability. Utilizing aluminum reduces material usage, enhances energy efficiency, and creates recyclable products. Additionally, we will discuss the impact of supply chain management, including insights from a case study on sustainable practices from Taber Extrusions’ sister company, National Material Company (NMC). These factors illustrate how a holistic approach to aluminum extrusion can lead to a more sustainable future.

              Aluminum Extrusion: A Sustainable Material Solution

              Aluminum extrusion offers unique advantages when it comes to sustainability. The process of shaping aluminum alloy into profiles allows for the development of lightweight yet strong components. This makes it ideal for industries aiming to reduce material usage without sacrificing performance. This material solution is especially beneficial in applications requiring high-strength and durable products, such as aluminum for infrastructure, automotive, and renewable energy sectors.

              Industry-Wide Sustainability Initiatives

              The aluminum extrusion industry, led by organizations such as the Aluminum Extruders Council (AEC), actively promotes sustainability initiatives. These include energy-efficient production practices, widespread use of recycled materials, and industry-wide sustainability reporting through the Environmental Product Declaration (EPD). By participating in these programs, companies ensure that sustainability efforts extend beyond individual manufacturers and set industry standards for sustainable development.

              • Automotive Applications: Lightweighting for Efficiency

              In the automotive industry, aluminum extrusions have become indispensable for vehicle light-weighting initiatives to improve fuel efficiency and reduce emissions. Replacing traditional steel components with aluminum extrusion profiles significantly reduces weight and enhances overall vehicle performance. For instance, automotive aluminum is utilized in structural components like crash management systems, suspension parts, and battery housings for electric vehicles. This shift supports sustainability efforts and meets the stringent requirements of the advanced high-strength steel (AHSS) standards. Therefore, vehicles are ensured to maintain high safety and quality benchmarks.

              • Aluminum in Renewable Energy

              The development of sustainable products in the renewable energy sector heavily depends on aluminum extrusion. Solar panel frames, wind turbine components, and electric vehicle charging stations are examples of extruded aluminum being used to provide strength, resistance to corrosion, and a lower environmental footprint. By integrating aluminum into these applications, energy consumption during manufacturing and installation is significantly reduced. The entire process is then more eco-friendly. Moreover, aluminum’s recyclability is critical in minimizing waste and supporting a circular economy.

              A close-up view of the underside of a solar panel array revealing structural details and wiring.

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              • Expanding the Reach: Industries Served by Aluminum Extrusion

              Beyond automotive and renewable energy, aluminum extrusions are crucial in aerospace, defense, and marine engineering industries. For example, aluminum’s lightweight and high-strength properties in aerospace applications contribute to improved fuel efficiency and load capacity. In the defense sector, extruded aluminum is used in protective structures and components for military vehicles to ensure high performance and durability. Also, the marine industry utilizes aluminum for shipbuilding, where its corrosion resistance enhances longevity in harsh environments.

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              Recyclability and the Circular Economy

              Aluminum is inherently sustainable due to its recyclability. Approximately 75% of all aluminum produced is still in use, showcasing its long-lasting value and efficiency. Recycling aluminum requires just 5% of the energy needed for primary production, which dramatically lowers the carbon footprint. This closed-loop approach ensures that the environmental benefits of aluminum extrusion are maximized across industries. Incorporating recycled content into the extrusion process further reduces the environmental impact and makes aluminum a key player in the global shift towards a circular economy.

              Research published in environmental science journals has shown that recycling aluminum results in significantly lower energy consumption than other metals, such as steel or copper. One study suggests that the process of recycling aluminum consumes just 5% of the energy needed for initial manufacturing. Thereby, this backs up broader initiatives to decrease industrial greenhouse gas emissions and preserve natural resources.

              The Role of Responsible Sourcing and Supply Chain Management

              Aluminum extrusion in sustainability extends to responsible sourcing practices and efficient supply chain management. Companies that prioritize sourcing ethically produced aluminum contribute to the broader industry initiative of transparent and accountable supply chains. This approach aligns with AEC’s EPD, which establishes uniform sustainability metrics across the industry and enables companies to achieve higher sustainability standards.

              Case Study: National Material Company (NMC) and Supply Chain Transparency

              A critical aspect of achieving sustainable aluminum extrusion is optimizing the supply chain to reduce waste and emissions. As detailed in a case study involving NMC, the integration of transparent supply chain practices was essential for addressing a customer’s request for a comprehensive global steel and aluminum parts supply chain footprint. The complexity of this task required NMC to analyze both direct and indirect emissions, as well as logistical processes. The company employed systematic approaches following GHG Protocol standards to accurately calculate emissions intensity based on the volume of metals processed.

              NMC’s experience highlights the importance of transparency in metal procurement, logistics, and processing to minimize embedded emissions. By collaborating with partners like Greenway Steel, NMC successfully demonstrates how thorough supply chain transparency can facilitate more efficient decarbonization efforts, ultimately paving the way for future sustainability targets in the metals industry.

              Partner with Taber Extrusions for Your Aluminum Extrusion Sustainability

              Taber Extrusions is a leader in the aluminum extrusion industry known for its commitment to sustainable manufacturing and product innovation. It serves industries including automotive, infrastructure, defense, and renewable energy with tailored aluminum extrusion solutions that adhere to the highest industry standards and focus on quality and environmental accountability. Offering vertically integrated services that encompass everything from billet casting to advanced machining, Taber’s facilities are equipped to handle the most demanding requirements.

              A technician wearing a hard hat, face shield, and protective gear, operating a liquid aluminum refining system (LARS).

              The company’s comprehensive approach to aluminum sustainability ensures that its processes meet and exceed regulatory standards. By continually seeking ways to enhance resource efficiency and reduce environmental impacts, Taber reinforces its position as a trusted partner for businesses looking to adopt more sustainable practices. Their dedication to sustainability extends to innovative design solutions and collaboration across industries to drive the next generation of green technology.

              Contact Taber today to learn how their solutions can help achieve your company’s aluminum extrusion sustainability objectives.

              About Aluminum Extrusion Sustainability Leader—Taber Extrusions

              Since 1973, Taber Extrusions has been a leader in the aluminum extrusion industry, renowned for innovation, quality, and exceptional service. As the only company in North America with a rectangular container, Taber can produce super-wide shapes and complex multi-void hollows, setting it apart in the market.

              Serving diverse industries such as aerospace, defense, infrastructure, and renewable energy, Taber combines technical expertise with a commitment to environmental responsibility. Headquartered in Russellville, Arkansas, with a regional sales office in Gulfport, Mississippi, Taber is dedicated to advancing aluminum extrusion sustainability and efficiency.

              Taber offers customized solutions that adhere to the highest industry standards, emphasizing quality and environmental stewardship. Their vertically integrated services—from billet casting to advanced machining—ensure superior products for any project.

              Partner with Taber Extrusions to create innovative and sustainable solutions for your next project.

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