Aluminum
Lightweight, corrosion-resistant metal with excellent machinability. Aluminum alloys (6061, 7075, 2024) are among the most widely used materials in CNC machining and sheet metal fabrication.
About Aluminum
Aluminum is the most widely used non-ferrous metal in manufacturing, valued for its exceptional strength-to-weight ratio, natural corrosion resistance, and outstanding machinability. With a density roughly one-third that of steel, aluminum alloys enable significant weight savings in aerospace, automotive, and consumer electronics applications without sacrificing structural integrity.
FabRapid machines aluminum alloys across the full spectrum from the general-purpose 6061-T6 to the aerospace-grade 7075-T6 and the high-formability 5052. Our CNC machining centers achieve tolerances as tight as ±0.005 mm on aluminum parts, and our sheet metal operations handle everything from laser cutting to complex multi-bend assemblies.
Aluminum is also one of the most versatile materials for surface finishing. It can be anodized in a range of colors, powder coated, bead blasted, or polished to a mirror finish. Type III hardcoat anodizing transforms the surface into an extremely wear-resistant layer suitable for sliding components and high-use applications.
Material Properties
Available Alloy Grades
6061-T6
The most versatile aluminum alloy with good strength, weldability, and corrosion resistance. Heat-treatable to T6 temper for enhanced mechanical properties.
Structural brackets, electronic enclosures, automotive parts, general-purpose machined components
7075-T6
High-strength aerospace alloy with tensile strength exceeding 500 MPa. Excellent fatigue resistance but lower corrosion resistance than 6061.
Aerospace structural components, high-stress fittings, military hardware, mold plates
2024-T3
High-fatigue-strength alloy commonly used in aircraft structures. Good machinability but requires protective coating for corrosion resistance.
Aircraft fuselage skins, wing structures, truck wheels, fasteners
5052-H32
Non-heat-treatable alloy with excellent formability and corrosion resistance. The best choice for sheet metal applications.
Sheet metal enclosures, marine hardware, fuel tanks, appliance panels
6063-T5
Architectural alloy with good surface finish and anodizing response. Lower strength than 6061 but excellent for extruded profiles.
Extruded heatsinks, window frames, decorative trim, railing systems
Compatible Manufacturing Processes
Aluminum can be processed using these manufacturing methods.
Available Surface Finishes
Surface treatments compatible with Aluminum.
Common Applications
Design Guidelines for Aluminum
Minimum wall thickness: 0.5 mm for CNC machining, 0.8 mm for sheet metal
Use radius ≥ 0.4 mm on internal corners to prevent tool breakage and stress concentration
For anodizing, specify uniform wall thickness to ensure consistent color — thin sections anodize darker
Avoid deep narrow pockets (depth > 4× width) to prevent tool deflection and chatter
Thread depth should not exceed 2× the nominal diameter for aluminum — deeper threads offer diminishing returns
When designing for sheet metal, keep bend radius ≥ material thickness to prevent cracking
Aluminum FAQ
6061-T6 is a general-purpose alloy with 310 MPa tensile strength, excellent weldability, and good corrosion resistance. 7075-T6 is a high-strength aerospace alloy with 570 MPa tensile strength but reduced weldability and corrosion resistance. Choose 6061 for most applications; use 7075 when maximum strength-to-weight ratio is critical.
Type II anodizing supports a wide range of colors including black, red, blue, gold, green, and clear. The color depth depends on the oxide layer thickness and the specific alloy — 6061 anodizes more uniformly than 7075. Custom Pantone matching is available for production orders.
Standard CNC tolerances for aluminum are ±0.05 mm. With precision machining, we can hold ±0.01 mm, and ultra-precision setups achieve ±0.005 mm. Aluminum is one of the easiest metals to machine to tight tolerances due to its excellent machinability.
Yes. Anodized aluminum (especially clear Type II anodizing) is FDA-compliant for food contact. The anodic layer creates a non-reactive, non-toxic barrier. Stainless steel is preferred for applications involving acidic foods.
Aluminum machines approximately 5-8× faster than stainless steel, resulting in lower part costs and faster lead times. It is one-third the weight but has lower strength and temperature resistance. Choose aluminum for weight savings and cost efficiency; choose stainless steel for corrosion resistance, strength at elevated temperatures, and food/medical applications.
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