As the global automotive industry accelerates toward electrification, lightweighting, and sustainable manufacturing, custom automotive aluminum extrusions have become one of the most influential materials shaping the future of mobility. From EV battery trays to body-in-white structures, high-strength aluminum extrusion profiles now replace heavier steel components, offering unmatched benefits in weight reduction, energy absorption, corrosion resistance, and design flexibility.
AluVoltec, a professional extrusion manufacturer with advanced facilities in Cambodia, delivers OEM-grade automotive aluminum profiles engineered to meet the strictest global standards. With full customization, precision tolerances, and a sustainability-focused production process, AluVoltec supplies extrusion solutions for EVs, commercial vehicles, off-road vehicles, and passenger cars.

Why Custom Aluminum Extrusions Are Essential for Modern Automotive Design

 
The demand for automotive aluminum parts continues to grow due to major industry trends:
1. Electrification
EV designers require lightweight materials to improve range and reduce battery load.
2. Crash Safety
Modern safety standards require high-energy absorption materials such as 6000- and 7000-series aluminum.
3. Sustainability
Automakers must reduce CO₂ emissions throughout the vehicle lifecycle.
4. Cost Efficiency
Near-net-shape extrusion reduces machining waste, tooling costs, and assembly steps.
Because of these advantages, automotive extrusion aluminum is now widely used in structural frames, battery systems, suspension parts, thermal systems, and interior reinforcement components.

Lightweight Yet Ultra-Strong: Up to 40% Vehicle Weight Reduction

One of the biggest advantages of aluminum extrusions is the ability to achieve 40% weight reduction compared to steel without compromising strength. This lightweighting directly impacts:
  • Fuel economy for ICE vehicles
  • Driving range for EVs
  • Handling and vehicle dynamics
  • Payload capacity for commercial vehicles

Aluminum Profiles Commonly Used in Lightweight Automotive Components

  • Auto aluminum beams for bumper systems
  • Automobile body profiles for doors, roof rails, and side impact structures
  • Auto aluminum racks and aluminum van racks
  • Storage aluminum profiles for interior modular systems
  • Aluminum rail kits, rolling tarps, and autoracks for commercial vehicles
With the ability to design multi-cavity, hollow, or reinforced sections, engineers can achieve high stiffness with minimal weight.

High-Strength 6xxx & 7xxx Automotive Alloys for Crash Safety

To meet demanding global vehicle safety regulations, AluVoltec offers customized extrusions using 6000- and 7000-series alloys, ensuring strength, ductility, and consistent crash behavior.

Alloy Series	Strength Level	Key Advantages	Automotive Applications
6061 / 6063 / 6082	Medium-high	Excellent formability, weldability, corrosion resistance	Chassis rails, battery tray frames, cross members
6005 / 6005A	High	Good balance of strength & toughness	Impact beams, structural profiles
7003 / 7005 / 7021	Very high	Superior crash resistance, high yield strength	Bumper beams, pillar reinforcements, crash boxes

These alloys ensure reliable deformation behavior in both high-speed and low-speed collision scenarios.

Sustainability Advantage: 95% Recyclable & Lower Life-Cycle CO₂

Sustainability is now a mandatory requirement for global automotive OEMs. Aluminum offers a significant environmental advantage:
• 95% Recyclable
Aluminum can be recycled repeatedly without losing mechanical strength.
• 95% Lower Energy for Recycled Aluminum
Recycled aluminum requires only ~5% of the energy needed to produce primary aluminum.
• Lower Vehicle Emissions
Lightweight extrusions reduce the energy needed to propel the vehicle.
AluVoltec integrates closed-loop recycling, energy-efficient furnaces, and low-waste extrusion practices to support environmentally conscious automotive manufacturing.

Custom Profiles for EV Battery Trays, Chassis & Body-in-White Structures

EV platforms require highly specialized structural components to support battery systems, crash safety, and thermal management. Custom automotive aluminum extrusions are ideal for these high-precision components.
Major EV & Automotive Extrusion Applications
  • Battery tray profiles & auto battery base frames
  • Body-in-white pillars, sills & roof rail profiles
  • Chassis cross members & side rails
  • Front & rear crash boxes
  • Reinforced hollow profiles for structural beams
  • Aluminum mobile towers & van racks
  • Aluminum autoracks & rolling tarp structures
With engineered cavities, reinforcement ribs, and integrated mounting channels, AluVoltec designs deliver high stiffness, low weight, and maximum safety.

Precision Extrusion Tolerances: Meeting OEM and Tier-1 Requirements

Automotive-grade aluminum extrusions require strict tolerances to ensure assembly accuracy and long-term structural integrity. AluVoltec uses:
  • High-tonnage extrusion presses (600–2500 tons)
  • Fully automated feed & cooling systems
  • Digital inline measuring systems
  • 3D optical scanners and coordinate measuring machines (CMM)

Typical Precision Capabilities

  • Wall thickness tolerance: ±0.08–0.15 mm
  • Straightness: ≤1.0 mm/m
  • Flatness: ±0.20–0.30 mm
  • Length tolerance: ±0.5–1.0 mm
  • Surface roughness after anodizing: Ra 0.6–0.8
These tolerances ensure perfect fitment with OEM assemblies and improve production efficiency.

From Design to Delivery: Complete Extrusion Engineering Process in 2026

AluVoltec provides a full end-to-end development and manufacturing process specifically for automotive projects.
1. Technical Consultation & FE Analysis
Engineers evaluate strength, stiffness, weight, crash behavior, and optimal profile geometry.
2. Alloy Selection & Mechanical Target Setting
Choosing the best 6000/7000 alloy based on vehicle requirements.
3. CAD Modeling & Profile Optimization
Including rib patterns, hollow sections, and thermal channels.
4. Extrusion Die Manufacturing
High-precision dies designed with simulation to ensure perfect metal flow.
5. Extrusion Production
Using advanced 600–2500T presses with controlled extrusion ratios and quenching cycles.
6. T6/T5 Heat Treatment
To ensure consistent hardness and mechanical strength.
7. CNC Machining & Cutting
Hole drilling, slotting, milling, tapping, and chamfering.
8. Surface Finishing
Anodizing, powder coating, sandblasting, brushing, and e-coating.
9. Final Inspection & Testing
Dimension testing, hardness testing, tensile testing, and corrosion evaluation.
10. Packaging & Delivery
Export-standard protection and fast overseas shipment.
This complete engineering chain ensures reliable performance for high-volume automotive manufacturing.

Surface Finishing Options for Automotive Applications

AluVoltec provides multiple finishing solutions to meet interior and exterior automotive requirements.

Anodizing

  • Adds corrosion and wear resistance
  • Provides metallic appearance
  • Ideal for visible profiles

Powder Coating

  • Excellent UV and weather resistance
  • Uniform and durable finish
  • Custom colors available

E-Coating

  • Extremely uniform coating
  • Perfect for complex hollow and multi-channel profiles
  • Popular for chassis and underbody components
Special textures, brushing, and polishing are also available for premium automotive aluminum parts.

Thermal Management: Heat Sink Extrusions for EV & Hybrid Systems

 
Thermal management is critical for EV batteries, controllers, and power electronics. Aluminum extrusion’s natural thermal conductivity makes it the preferred material for:
  • Battery cooling plates
  • Motor controller heat sinks
  • Inverter cooling systems
  • High-density fin heat sink extrusions
Extrusion allows precise control over fin geometry to maximize heat transfer without adding weight.

Cost Savings Through Design Optimization & Near-Net-Shape Extrusion

Custom automotive aluminum extrusions significantly reduce production costs through:
• Less machining
Functional features are integrated directly into the profile.
• Lower assembly cost
Fewer welding and joining operations.
• Reduced material waste
Near-net-shape extrusion produces minimal scrap.
• Longer tooling life
Extrusion dies last for high production volumes.
AluVoltec’s design engineers work with clients to optimize both performance and total manufacturing cost.

Case Studies: How AluVoltec Supports Global Automotive Projects

1. EV Battery Tray Project – 2025

  • Custom 6082-T6 hollow profiles
  • Integrated cooling channels
  • 21% weight reduction compared to steel
  • Lower thermal resistance for battery safety

2. Passenger Car Body-in-White Reinforcement

  • 7005 extruded crash-resistant profiles
  • Increased structural rigidity by 17%
  • Eliminated multi-piece welded steel assembly

3. Commercial Vehicle Aluminum Rack System

  • High-strength storage aluminum profiles
  • 32% lighter than steel racks
  • Higher corrosion resistance for long-term outdoor use
These results demonstrate AluVoltec’s ability to serve OEMs, Tier-1 suppliers, and specialized vehicle manufacturers.

Lead Times & MOQ: Fast, Flexible Production in Cambodia

AluVoltec provides one of the best delivery capabilities in Southeast Asia:
  • Fast prototype development
  • Flexible MOQ for both small and large projects
  • Cost-effective production for global automotive customers
  • Duty-free export advantages to multiple countries
Our Cambodia manufacturing location ensures stable production capacity, competitive costs, and efficient export logistics.

Start Your Custom Automotive Extrusion Project Today

Whether you need battery tray profiles, auto aluminum beams, aluminum mobile towers, vehicle extrusion aluminum, automotive aluminum extrusions, or custom structural profiles, AluVoltec provides end-to-end engineering and manufacturing support.
Contact us today to receive a free quotation and begin developing your custom automotive extrusion solution.