The global automotive industry is moving faster than ever toward lightweight design, higher safety standards, and electric vehicle innovation. At the center of this transformation lies one material: auto extruded aluminum profiles. These customized profiles deliver outstanding strength-to-weight performance, crashworthiness, and thermal efficiency—features that modern vehicles heavily rely on.
Today, top automobile manufacturers use automotive aluminum extrusions in structural frames, EV battery trays, motor housings, crash beams, suspension systems, and countless other components. With sustainability, efficiency, and performance becoming essential requirements, auto aluminum profiles have become the preferred choice over traditional steel.
This article covers the top 10 uses of auto extruded profiles, supported by technical benefits, weight reduction data, advanced surface treatments, and key trends shaping next-generation EVs and autonomous vehicles.
 

What Are Auto Extruded Profiles & Why They Matter in Automotive Manufacturing

Auto extruded profiles are high-precision aluminum components produced by pushing heated aluminum billets through a steel die. This process gives manufacturers unmatched design flexibility and helps produce strong, lightweight structures with complex geometries.
Why Automotive Engineers Prefer Extruded Aluminum Profiles
  • 30–40% lighter than steel, enabling major weight reduction
  • Excellent energy absorption during collisions
  • Superior corrosion resistance for long-lasting vehicle parts
  • High thermal conductivity—ideal for EV cooling systems
  • Lower tooling cost compared to stamping or casting
  • Infinite customization options for shapes, channels, and wall thickness
  • Suitable for structural, mechanical, and thermal applications
  • Fully recyclable, supporting green manufacturing
Thanks to these advantages, automotive aluminum extrusions are now standard in both traditional vehicles and EV platforms.
 

Top 10 Uses of Auto Extruded Profiles in Modern Vehicles

 

1. Battery Trays, Bases & Enclosures for Electric Vehicles (EVs)

The rise of electric mobility has significantly increased demand for EV battery tray extrusion. Battery packs require lightweight but extremely rigid enclosures to support and protect hundreds of cells.
Why Aluminum Extrusions Are Perfect for EV Battery Trays
  • High stiffness-to-weight ratio
  • Excellent thermal management for cooling plates
  • Corrosion-resistant against electrolytes
  • Easy integration of channels for liquid cooling
  • Supports structural battery pack designs
Aluminum battery tray profiles also improve EV range and ensure safer performance during impacts, making them one of the most critical automotive aluminum extrusions on the market.

2. Crash Management Systems: Bumper Beams & Impact Structures

Safety is a non-negotiable priority in modern vehicles. Crash beam aluminum extrusion is widely used because aluminum absorbs impact energy more efficiently than steel.
These components include:
  • Aluminum bumper beams
  • Front and rear crash boxes
  • Door impact bars
  • Longitudinal crash rails
Extruded crash structures deform predictably during collisions, helping protect passengers and reduce repair costs.

3. Lightweight Automotive Body Structures & Subframes

As part of vehicle lightweighting programs, OEMs are replacing steel with automobile body profiles for:
  • Side members
  • Floor structure supports
  • Door frames
  • Roof structures
  • Tailgate reinforcement
The use of 6000 series aluminum automotive profiles significantly improves body rigidity while reducing vehicle mass—essential for EVs where battery weight is already high.

4. Roof Rails, Crossmembers & Luggage Systems

Automakers rely on lightweight aluminum extrusions for roof-mounted components such as:
  • Roof rails
  • Crossmembers
  • Load-bearing luggage racks
  • Aluminum rail kits
  • Aluminum mobile towers
  • Aluminum van racks
These parts require high strength, weather resistance, and aesthetic finishes—qualities aluminum extrusions provide naturally.

5. Motor Housings, Cooling Channels & Thermal Structures

EV and hybrid powertrains generate substantial heat. Extruded aluminum is ideal for motor housing extrusion because it provides:
  • High heat dissipation
  • Vibration resistance
  • Customizable shapes for integrated cooling channels
  • Excellent structural protection
Combined with cooling fins and channels, extruded profiles ensure long-term stability and high performance for electric motors and inverters.

6. Seat Frames, Tracks & Adjustment Mechanisms

Modern automotive interiors require strong yet lightweight components. Extruded aluminum is used in:
  • Seat bases
  • Backrest structures
  • Recliner assemblies
  • Sliding and height-adjustment rails
These components reduce weight while maintaining durability, allowing automakers to integrate more advanced comfort and safety features.

7. Chassis Reinforcement, Suspension Members & Undercarriage Systems

The chassis is one of the most critical structural elements of a vehicle. Automakers increasingly use aluminum chassis components because they:
  • Reduce total vehicle mass
  • Improve rigidity
  • Enhance handling
  • Provide excellent corrosion resistance
Common extruded components include:
  • Suspension arms
  • Subframe crossmembers
  • Chassis rails
  • ​​​​​​​Underbody protection structures
Aluminum’s ability to combine strength and reduced weight makes it ideal for modern chassis engineering.

8. Thermal Management Systems: Heat Sinks & Cooling Profiles

Thermal management is essential for EVs, hybrid vehicles, and vehicles with high-powered electronics. Thermal management aluminum profiles are used in:
  • Heat sinks
  • Cooling plates
  • Battery thermal channels
  • LED lighting cooling structures
  • ​​​​​​​Power control module cooling systems
Because aluminum disperses heat quickly, it ensures electronic reliability and protects sensitive components from thermal damage.

9. Door Impact Beams, Side Sill Bars & Anti-Intrusion Structures

Side collisions are highly dangerous. Automakers use side impact beam extrusion for:
  • Door reinforcement beams
  • Side sill reinforcements
  • ​​​​​​​Internal A- and B-pillar structural supports
These extruded components absorb crash energy and prevent passenger compartment intrusion, significantly enhancing crash safety ratings.

10. Window Frames, Sunroof Structures & Sealing Guides

Precision-tooled aluminum extrusions play a major role in interior comfort and exterior sealing systems. They are used in:
  • Sunroof frames
  • Window guide rails
  • Sliding channels
  • ​​​​​​​Weather strip supports
These components are lightweight, dimensionally stable, and corrosion-free—making them reliable for long-term automotive use.
  

Key Advantages of Aluminum Auto Extruded Profiles Over Steel

 

Aluminum extrusions outperform steel in multiple areas:
1. Major Weight Reduction
Vehicle weight can be reduced by 30–40%, improving:
  • EV range
  • Fuel efficiency
  • Acceleration
  • ​​​​​​​Braking
2. Superior Corrosion Resistance
Aluminum naturally resists rust without heavy coatings.
3. Excellent Crash Energy Absorption
Ideal for bumper beams and crash structures.
4. Exceptional Thermal Conductivity
Critical for EV batteries, motors, and electronics.
5. Flexible & Customizable Design
Extrusion allows complex shapes and multi-chamber profiles.
6. Recyclability
Supports global emission reduction targets.

How Auto Extruded Profiles Reduce Vehicle Weight by 30–40%

Weight reduction is one of the top priorities for automotive OEMs. Replacing steel with vehicle weight reduction extrusion offers:
  • Lighter structural parts
  • Improved EV driving range
  • Better fuel economy
  • Reduced carbon emissions
  • ​​​​​​​Enhanced handling and towing capacity
Extrusions enable engineers to merge multiple steel parts into a single aluminum profile, lowering assembly time and cost.

Surface Treatment Options for Automotive Aluminum Extrusions

To improve durability and appearance, auto aluminum profiles undergo specialized surface treatments:
  • Anodizing – corrosion resistance & aesthetic finish
  • Powder coating – impact protection & color options
  • E-coating – uniform coverage for complex shapes
  • Chemical conversion coating – better paint and adhesive bonding
  • Polishing or brushing – premium appearance
  • Sandblasting – matte texture and improved adhesion
These coatings ensure long-term performance even in harsh environments.

Future Trends: Automotive Extrusions in EVs & Autonomous Vehicles

The automotive industry is transitioning toward electrification and intelligent mobility. Aluminum extrusions will play an even bigger role in:
1. Structural Integrated Battery Packs
Extruded frames integrated directly into vehicle flooring.
2. Gigacasting Replacement
Large extruded components replacing multiple welded steel parts.
3. Autonomous Sensor Mounting
Lightweight housings for LiDAR, radar, and camera systems.
4. High-Efficiency Cooling Profiles
Advanced channels for fast-charging EV batteries.
5. Ultra-Light Crash Structures
Next-gen crash beams engineered for maximum energy absorption.
These innovations will expand the demand for automotive aluminum extrusions globally.

Conclusion

From battery trays and crash beams to motor housings and roof structures, auto extruded profiles are at the core of modern vehicle engineering. Their unmatched combination of low weight, high strength, thermal performance, and corrosion resistance makes them essential for today’s automotive manufacturing.
As EV adoption accelerates and autonomous driving becomes mainstream, the need for lightweight, efficient, and high-strength aluminum profiles will increase dramatically. Companies that invest in automotive extrusion technology will be better positioned to support global OEMs and lead the future of mobility.