Aluminum is the most widely machined metal — light, strong, corrosion-resistant and highly machinable. Choosing the right grade and finish is the difference between a good part and a great one.
Choosing the Right Grade
6061 offers the best balance of strength, machinability and cost for general parts. 7075 provides aerospace-grade strength but costs more. 5052 and 6063 suit sheet forming and extrusions respectively.
Machinability & Speed
Aluminum cuts fast with excellent chip control, so cycle times are short and tool life long. This makes it the most economical metal to machine at volume.
Surface Finishes
Anodizing (clear, colored or hard) is the most common finish, improving corrosion resistance and appearance. Other options include bead blasting, brushing, powder coating and polishing.
Design Rules for Aluminum
Maintain consistent wall thickness, use generous internal radii, and avoid sharp internal corners to reduce stress and tool wear. Keep pocket depth-to-width ratios within recommended limits.
Common Applications
Aluminum is everywhere — smartphone and laptop housings, heat sinks, audio panels, UAV frames, camera bodies and automotive lightweight parts.
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