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Why Chicago for Extrusion?
95,000
Manufacturing Workers
5,800
Manufacturing Facilities
2,665,039
City Population
Chicago, Illinois is part of the Chicago-Naperville-Elgin metro area and is home to major manufacturers including Abbott Laboratories, Boeing, Caterpillar. The Great Lakes region offers a strong manufacturing base making it an ideal location for extrusion services.
Extrusion Capabilities
Extrusion is a manufacturing process where material is forced through a shaped die to produce parts with a continuous cross-sectional profile. Metal extrusion (primarily aluminum) involves heating billets to 700-900°F and pushing them through steel dies using hydraulic rams generating thousands of tons of force. Plastic extrusion melts pellets in a screw-driven barrel and forces the material through a die continuously. Aluminum extrusion produces an enormous variety of profiles used in construction (window frames, curtain walls), transportation (automotive, rail, aerospace), electronics (heat sinks), and industrial applications. Custom die shapes enable unique cross-sections at relatively low tooling cost.
±0.005"-±0.015" for aluminum profiles; tighter with secondary machining
2-6 weeks for new dies; 1-3 weeks for production from existing dies
$500-$5,000 for dies; $2-$20/lb for aluminum profiles
Industries Using Extrusion in Chicago
Major Manufacturers in Chicago
Key employers in the Chicago manufacturing sector include:
- Abbott Laboratories
- Boeing
- Caterpillar
Extrusion in Chicago — FAQ
How many Extrusion providers are in Chicago, IL?
The Chicago-Naperville-Elgin metropolitan area has approximately 5,800 manufacturing establishments, many of which offer extrusion services. The area employs about 95,000 manufacturing workers, ensuring a skilled workforce for your project.
How much does an extrusion die cost?
Aluminum extrusion dies typically cost $500-$5,000 depending on complexity and size. Simple solid profiles may cost $500-$1,000. Complex hollow profiles with multiple chambers can cost $3,000-$5,000. Dies last for thousands of feet of extrusion before replacement.
What is the minimum order for aluminum extrusion?
Most extruders have minimum order quantities of 500-2,000 lbs, which translates to several hundred to several thousand feet depending on the profile weight. Some custom extruders accept smaller orders at premium pricing.
What aluminum alloys are commonly extruded?
6063 is the most common extrusion alloy, offering excellent extrudability, corrosion resistance, and anodizing response. 6061 provides higher strength for structural applications. 7075 is used for aerospace applications requiring maximum strength.
Can extrusions be machined after forming?
Yes, aluminum extrusions are frequently machined after forming to add holes, slots, pockets, and threaded features. CNC machining of extrusions is very common and cost-effective because the extrusion provides the overall shape while machining adds details.
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