The Power of Aluminium The aluminium extrusion process provides virtually unlimited opportunities to the product designer with the added benefit of low tooling costs and short lead times. But it is not just in new product design where aluminium extrusions are leading the way. In existing products, substitution of other materials and processes by aluminium extrusions can result in major cost savings through fewer components, reduced finishing, simplified assembly and improved supply chain logistics. Clip-fits, screw-ports and circuit-board location grooves are just a few ways of reducing components and simplifying assembly at no additional cost. Aluminium’s excellent corrosion resistance means that often no finishing is required. However, if additional corrosion resistance or aesthetics are important, there is a whole range of suitable finishing processes from polishing and brushing through to anodising and painting. The anodising process offers unique benefits in terms of protection with almost no impact on the components eventual recyclability. It can be that the low cost tooling, quick turnaround and the ability to produce a range of different length components from stock lengths can transform the supply chain. A leading supplier of electric motors shifted his production from aluminium castings. This not only revolutionised the production process but also resulted in increased strength, improved thermal conductivity and reduced risk for corrosion for the housings. Different length motor housings can be produced from stock lengths, new designs can now go from the drawing board to production in 4 to 6 weeks at only a fraction of the tooling costs.