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High-performance aluminium extrusions for industries with zero margin of error: aviation, defense and space

When every micron matters: aluminium extrusion profiles with size tolerances from ± 0.02 mm

Innovation in aviation, space, and defense continues to push boundaries of engineering. As technologies evolve, the demand for lightweight materials, complex geometries, and high-precision components becomes increasingly important in these mission-critical industries.

In this article, we explore high-precision aluminium profiles in aviation, space, and defense, and how their unique properties contribute to the performance of critical applications.

What are the advantages of high precision aluminium extrusions?

High-precision aluminium extrusions offer several advantages for aerospace and defense applications, particularly when designs require complex geometries, tight tolerances, and lightweight construction. At Mifa, the precision extrusion profiles are tailored to specific technical requirements and component designs.

The advantages of aluminium extrusions from Mifa include:

  • Complex geometries
  • High dimensional accuracy
  • Lightweight construction
  • Design integration
  • Material selection
Tolerances From ± 0.02 mm
Minimum order From 10 kg for protos
Maximum quantity Unlimited
Profile size From ø 3 mm to ø 180 mm
220 x 60 mm
Profile weight From 0.003 kg/m to 10kg/m
Surface roughness From Ra 0.3 in extrusion direction
Wall thicknesses From 0.25 mm

Aerospace aluminium alloys: choosing materials for aviation, defense and space

Aerospace aluminium alloys play an important role in aviation, defense, and space applications, where low weight, high strength, and reliable performance are essential. The choice of aluminium alloy depends on the function of the component, operating environment, and required properties.

Common aircraft aluminium alloys include 6061 and 6082 from the 6000 series, which offer a combination of strength, corrosion resistance and good extrudability. The 7000 series, including 7075, is known for its high strength-to-weight ratio and is used in demanding structural applications.

For defense applications, aluminium alloys are selected based on requirements such as:

  • Structural strength
  • Durability
  • Corrosion resistance
  • Weight reduction.

In space applications, the selection of materials must also account for thermal variations, dimensional stability, and the specific demands of space environment. Space-grade aluminum alloys are aluminium alloys selected and qualified for the requirements of spacecraft and satellite applications, where material properties, reliability and compliance are critical.

Concluding, for high precision aluminium extrusion profiles, selecting the right alloy is only part of part of the process. The alloy must also be suitable for extrusion and the required geometry, tolerances and mechanical properties. Matching the material – alloy – to the application is essential to achieving the required performance in aviation, defense and space systems.

  • Example alloy specifications

     

    Alloy Application Min. Rm (Mpa) Min. Rm 0,2 (Mpa) Max. design freedom Speed Relative tolerances Solid profile Hollow profile
    7020 Stress defence & aerospace 490 290 + 25 80 Y Y
    7075 Defense en aerospace 540 470 – 20 60 Y N

What are key considerations for designing aluminium profiles in aerospace and defense?

Choosing the right alloy is an important part of the engineering process. The material properties must align with the desired profile geometry, the extrusion process, and any subsequent CNC machining or surface treatments.

By evaluating different alloy options, engineers can identify the most suitable materials for precision-extruded profiles and make informed decisions early in the design process.

Aerospace and defense applications have high demands on materials and components. To meet these requirements, suppliers like Mifa balance several critical factors:

  • Weight reduction: minimising weight without compromising structural integrity
  • Dimensional accuracy: meeting tight tolerances and complex design specifications
  • Strength and durability: withstanding demanding operating conditions, such as extreme temperatures and mechanical loads
  • Reliability and quality: ensuring consistent performance in mission-critical applications

High-precision aluminium extrusion profiles combine these properties with design freedom, making them a valuable solution for the demanding requirements of aerospace and defense.

About Mifa: market leader in aluminium precision extrusion

Since 1975, Mifa Aluminium has been producing high-precision aluminium extrusion profiles, completing its first aerospace project exactly one year later. In 2013 Mifa became AS9100 certified for the first time, validating the continuous quality and high standards for the aerospace industry. With half a century of experience, Mifa has developed in-depth knowledge of the technical requirements and challenges associated with these demanding applications.

Part of stocklisted company Aalberts

Mifa is part of the publicly listed company Aalberts, and, together with Aalberts, invests in high-quality and innovative technologies. This ensures we always have access to the best technologies and machines to produce your products. For the aerospace market, Mifa works closely with other companies within Aalberts. This collaboration ensures both quality and financial stability.

Aalberts logo wit

A reliable custom aluminium extrusion partner

Our high-quality extrusion profiles are ensured through rigorous process monitoring and strict product control. Mifa is certified to AS9100 (also known as EN 9100), the internationally recognized quality standard for the aerospace industry. As an extrusion company that is AS9100 certified, Mifa is a market leader and expert for custom aluminium precision extrusion parts in Europe and the United States.

Collaboration to precision engineering

Developing the right aluminium extrusion profiles starts with understanding the application’s specific requirements. From selecting the appropriate aluminium aerospace alloy to exploring geometries, specifications and prototyping possibilities; early collaboration helps identify the most suitable solution.

Mifa Aluminium’s engineers are available to discuss all of the above points and help you further with design and choose of right material.

Have a specific application or technical challenge in mind? Contact our engineering team to discuss your requirements.

Pascal Caërou, segment leader aerospace

Contact us for more information

Call or email Pascal

Segment Leader Aerospace

Pascal Caërou

+31 (0)77 389 88 88