Once you have your CAD model, choosing the appropriate quality of material for your frame is crucial. There are several factors to consider, such as strength and weight requirements. Below are the available aluminum alloy series’ you can choose from:

• Series 1000 – also known as pure aluminum, this metal series is known for its flexibility and softness. It is often used to make frames that require complex shaping, bending and forming. It is also valued for its high ductility, corrosion resistance and brilliant color.
• Series 2000 – This alloy series is characterized by high mechanical strength and machinability. Its strength and corrosion resistance make it a popular choice for structural applications.

Also, the 2000 series alloys, like the 2011, 2014 and 2024 alloys, are among the most commonly used due to their incredible strength and fatigue resistance. They are usually the best choice when a project requires a good balance between weight and strength.

• Series 3000 – The 3000 Series is also among the most commonly used aluminum alloys to manufacture custom aluminum frames. They provide excellent all-around performance and durability in lighter and heavier frames
• Series 5000 – This aluminum alloy isn’t heat treatable but is strong and durable. It’s a good choice for lightweight frames subjected to little wear. It’s also corrosion-resistant.
• Series 6000 – The 6000 Series aluminum alloys are also non-heat-treatable and versatile. In fact, of all the non-heat-treatable aluminum grades, they’re the most versatile.

This category is also very corrosion resistant and has excellent mechanical properties.

When annealed, a series 6000 aluminum alloy is extremely ductile and can be welded using various techniques.

This corrosion-resistant alloy series is commonly used for architectural framing because of its high tensile strength and excellent machinability. It is popular for both interior and exterior architectural frames.

• Series 7000 – This alloy series is stronger than the 6000 Series but more expensive. It is recommended only for custom frames that require the highest durability.

But like the 6000 series, it is easier to shape and form in the annealed condition and responds well to heat treatments such as spot and flash welding.

Tubes, beams, pipes or plates are used to make aluminum frames. This means the aluminum metal must be formed into these structures before the frame is cut and assembled.

Aluminum tubes can be formed into cylindrical or square shapes. Depending on the intended use, they can be made with different outer and inner diameters and different alloys.

It’s advisable to determine the maximum bend radius and temperature range you need for your particular application based on the pressure rating.

For high-temperature applications, it’s advisable to use heat-treated aluminum that can withstand high temperatures. Aluminum works very well at low temperatures but needs heat treatment to withstand high temperatures.

Tubes are also preferred for artistic applications, especially picture frames, because various processes, chemicals and electricity can easily color them.

Last but not least, nuts, bolts, rivets and welds allow aluminum tubes to be securely joined in various formations for frame fabrication.

Similarly, aluminum beams and tubes can be made in various shapes and sizes for aluminum frame fabrication.

The reason why aluminum tubes, beams and pipes are widely used is that they’ve high strength, especially in the construction industry.

However, there are many cases where aluminum sheets are preferred. Using sheet metal instead of tubing beams and pipes to make custom aluminum picture frames means less weight and lower cost.

Many window frames, tabletop frames, poster frames and document frames are also made from aluminum sheets.

The following techniques are commonly used to complete this step (making aluminum tubing, beams, pipes and plates):

• Aluminum extrusion
• Aluminum casting
• Aluminum forging
• Aluminum rolling (hot rolling and cold rolling)

Aluminum window frame

In this step, the aluminum structure created above is cut to size required to produce the custom aluminum frame.

Aluminum cutting can be done by sawing, chiseling or shearing. For each technique, there are both manual and motorized alternatives.

In addition, it’s also possible to cut aluminum structures with torches. In this case, hand torches are used, either plasma torches or oxyacetylene torches. The latter is powered either by acetylene or propane gas. Propane gas is cheaper, but it requires special cutting nozzles.

For high-precision cutting, you can use numerically controlled cutters in a process known as CNC machining.

CNC machining can use laser cutting, waterjet cutting or milling tools to cut through structures. All you’ve to do is enter the desired parameters into the CNC machine and press start. The machine will cut the pipe, beam or plate as the computer design specifies.

As you can imagine, this method is especially useful for complicated or very detailed projects.

This step completes the main fabrication process.

The formed and machined parts and components are assembled and welded according to the design drawing.

Gas metal arc welding is the preferred welding process for aluminum metal fabrication. In this case, you connect the welding torch to a positive terminal, and the current is direct current (DC).

You’ll also need a filler wire to continuously pass through the torch while directing the shielding gas onto the workpiece.

Aluminum shelf frame

Now that your frame is finished, it’s time to give it a suitable finish.

Remember that not all but some custom aluminum frames will require additional finishing treatments to meet specifications as designed.

Some common metal surface treatments are grinding, painting, powder coating, thermal spraying, engraving and metal etching.

Remember to choose a finish best suited for the intended application of the frame. For example, if the frame is to be used for an outdoor architectural application, you should choose a finish that can withstand extreme outdoor conditions (UV rays, humidity, etc.).

Since it’s an architectural application, you should also ensure that the finish meets the desired aesthetic standards. A good choice in both cases would be aluminum anodizing. It is a decorative and protective finish with excellent durability and corrosion resistance.

Powder coated aluminum window

The final product is inspected and undergoes a series of tests to ensure its functionality, strength, durability, and safety.

These quality tests are usually performed using samples, but other methods can also be used. Once it’s ensured that the quality of the custom aluminum frame meets the established standards and the customer’s specific requirements, the product is released with the appropriate documentation.

Overall

You can be sure that you’ll receive high-quality aluminum frame fabrication products from a reputable company that meets all standards.

High-quality solutions for aluminum framing systems are waiting for you to discover. Work with a leading custom sheet metal fabrication factory in China