Aircraft Extrusion

Aircraft extrusion offers high-performance 2024, 6061, and 7075 aerospace aluminum profiles, with over 33, 000 part numbers ready to ship.

We specialize in custom and standard extrusions for airframe structures, with fast lead times, in-house CNC, and full design support—trusted by Boeing, Airbus, and top OEMs.

Aircraft extrusion specifications

• Certified under the AS9100 quality management system to ensure full consistency and traceability.
• Compliant with ISO 9001:2015 and AS9100:2016 Rev D standards.
• AS9120 certified to support aerospace supply chain and warehouse management.

Each batch comes with full chemical composition and mechanical property reports. All materials meet REACH and RoHS standards. Quality records are permanently retained to ensure full traceability across the aerospace industry.

Aircraft extrusion alloys

Aerospace aluminum extrusions products

Chalco understands the aerospace industry's high demands for lead time, compliance, and cost control. With in-stock inventory, fast response, and full traceability, we help reduce AOG downtime and lower material costs.

We offer not only aluminum and titanium aerospace extrusions, but also custom profiles, CNC prototypes, seat components, and cargo nets—supporting everything from hand-drawn sketches to full 3D CAD models.

Aircraft aluminum tube pipe

As one of the reliable aircraft aluminum tubing suppliers, Chalco specializes in the development and customization of aviation aluminum tubing for applications requiring a high strength-to-weight ratio.

We offer a wide range of standard and non-standard profiles, including square, rectangular, and complex-shaped tubes, engineered to meet the structural demands of modern aerospace and performance-driven industries. Quick Quote

Aircraft Aluminum Round Tubing

Aircraft aluminum round tubing offers high strength, lightweight properties, and excellent fatigue resistance, making it ideal for aircraft structures, supports, and hydraulic systems.

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Aircraft Aluminum Square Tubing

Aircraft aluminum square tubing is strong, lightweight, and ideal for structural aerospace use.

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Aerospace-grade rectangular tubing

Aerospace-grade rectangular tubing offers excellent strength and rigidity, ideal for fuselage structures and frame reinforcement.

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Aircraft aluminum seamless tubing

Aircraft aluminum seamless tubing offers high strength and a smooth, uniform structure for critical aerospace applications.

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Aircraft aluminum drawn tubing

Aircraft aluminum drawn tubing provides enhanced strength, tight tolerances, and a smooth finish for precision aerospace components.

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BAC1501 Boeing tubing

We offer a wide range of aircraft tubing that meets Boeing BAC1501 specifications in 2024 and 7075 alloys.

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Our inventory mainly includes extruded and drawn tubing. Drawn tubing is primarily available in 2024-T3 AMS-WW-T-700/3 and 7075-T6 AMS-WW-T-700/7.

For extruded tubing, we offer 2024-T3511 AMS-QQ-A-200/3 and 7075-T6511 AMS-QQ-A-200/11.

Browse our full aircraft aluminum tubing inventory, including round, square, rectangular, seamless, and drawn options in various alloys and sizes. Quick Quote

2024 Aircraft Drawn Aluminum Tube

7075 Aircraft Aluminum Tube

7005 Aluminum Tube Pipe

Aircraft extrusion standard shapes

Standard aircraft extrusions are available in a variety of shapes such as angles, channels, tees, and zee profiles for structural aerospace applications.

Aluminum Angle

H Profil Aluminium

Aluminum Channel

Beam Aluminium

Aluminum Z Profile

Aluminium T Profile

Aluminum C Channel

Aluminum Hat Channel

F Channel Aluminum Extrusion

Custom shapes available to meet your specific aerospace design requirements.

Interested in these shapes? Feel free to request a quote, ask questions, or learn more. Quick Quote

Boeing (BAC) extrusions

We maintain a large inventory of Boeing (BAC) extrusions with thousands of shapes available, typically in 10, 12, 20, and 24-foot lengths.

BAC1504 Angle, Bulb

BAC1515 Angle, Bulb, Misc

BAC1514 Angle, Misc

BAC1509 Channel

BAC1510 Channel, Misc

BAC1507 Double-Leg Tee

BAC1508 Double-Leg Tee, Misc

BAC1511 Filler (Solid Bar)

BAC1513 Filler, Misc

BAC1519 Forks & Fittings

BAC1520 Misc Shapes

BAC1506 Tee, Misc

View in-stock BAC extrusions (Boeing shapes) and contact us for the complete size list. Quick Quote

AND extrusions

We offer standard aerospace and aircraft extruded shapes, including Army Navy drawing extrusions, with thousands of part numbers in stock and typical lengths of 10, 12, 20, and 24 feet—ready for your aerospace project needs.

AND10133 Equal Leg Angle

AND10134 Unequal Leg Angle

AND10135 Bulb Angle

AND10136 Tee

AND10137 Channel

AND10138 Equal Leg Zee

AND10139 Unequal Leg Zee

AND10140 H Beam

AND10141 Bulb Tee

Aircraft seat track extrusion

Chalco offers in-house CNC machining capabilities for various aircraft grades, including 2024, 6061, and 7075, with lengths up to 12 feet (approx. 3.6 meters).

All manufactured tracks come with OEM certification and full traceability. First Article Inspection (FAI) and material certificates are provided in all cases.

Aircraft seat track extrusion is a high-strength structural profile used to secure and adjust seat positions in aircraft cabins.

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Other shapes:

Type A

Type B

Type C

Type D

Type E

Type G

Popular aircraft component extrusions by Chalco

Chalco's best-selling aircraft components include extruded aluminum wing spars, folding screen profiles, and stringer extrusions—widely used in both commercial and military aircraft structures.

6061-T6 Aluminum Streamline Struts

All streamline struts are made from 6061-T6 extruded aluminum for excellent strength, corrosion resistance, and aerodynamic performance.

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Extruded aluminum wing spar material

Made from 6061-T6 extruded aluminum with an ultimate tensile yield strength of 45, 000 PSI and shear yield strength of 30, 000 PSI.

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Extruded L & T Cap Strip

Extruded L & T Cap Strip

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Aluminum folding screen profiles for airport use

These profiles are made from 6061/6063 aluminum alloys, comply with GB/T 6892-2015 standards, feature an anodized finish, and are packaged with anti-static film and shrink wrap.

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Aircraft aluminum ribs

Aluminum alloy ribs used inside aircraft wings offer a lightweight, high-strength structure designed to support the skin and withstand flight loads.

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Aircraft hinge extrusions

Aircraft hinge extrusions are used for connecting movable parts like doors and control surfaces, offering high strength, light weight, and corrosion resistance.

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Aircraft aluminum roll form stringers

Specific part numbers are available from our extensive inventory of thousands of shapes. Typical length is 12 feet.

BAC 1490 Angle 90 Degrees

BAC 1489 Angle, Acute/Obtuse

BAC 1494 Channel C-Section

BAC 1495 Channel C-Section

BAC 1500 Channel Flanged

BAC 1493 Channel U-Section

BAC 1492 Misc

BAC 1496 Misc, Channel

BAC 1517 Zee

Aircraft aluminum roll form stringers are available in 2024, 6061, and 7075 alloys (bare and clad), with tempers including O, T3, T4, T6, T62, T73, and T42, per AMS-QQ-A-250 standards—specific part numbers in stock, typical length 12 feet.

Aircraft aluminum bar

Aircraft aluminum bar offers high strength and machinability, making it ideal for aerospace structural components and precision-machined parts.

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2024 2A12 Aerospace Aluminum Rod Bar

7075 Aviation Aluminum Bar Rod

7050 Aerospace Aluminum Bars

Miniature aluminum extrusions

Miniature aluminum extrusions for aircraft are precision profiles used in tight-space structural or interior applications where lightweight and strength are critical.

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Miniature aluminum extrusions for aircraft are precision profiles used in tight-space structural or interior applications where lightweight and strength are critical.

Aerospace aluminum alloys and specifications overview

Mechanical properties of aerospace alloys 6061, 2024, and 7075

All properties shown in the table are taken from the QQ-A-200 specification.

Aircraft extrusion dimensional tolerances

Profile tolerance is a key factor in extrusion design, and Chalco understands aluminum processing inside and out.

For every part we produce, we carefully consider wall thickness, circumscribing circle diameter, dimension placement, and profile type, selecting the appropriate extrusion press to meet tolerance requirements. Quick Quote

Who are our customers?

As a specialized aircraft extrusion company, Chalco stocks over 2, 000 models of 2024 and 7075 series extrusions, supporting both imperial and metric sizes in standard and non-standard shapes.

We are a recognized supplier to Spirit Aerosystems, the world's largest Tier 1 aerospace structure manufacturer, and maintain long-term partnerships with major aerospace organizations, including:

• OEMs and airframe manufacturers: Boeing, Airbus, Lockheed Martin, Embraer, Bombardier
• Airlines and operators: Malaysia Airlines, Cargolux, Ryanair
• Advanced manufacturing companies: SpaceX, GE Aviation, Raytheon, Pratt & Whitney, Rolls-Royce, Sikorsky, Moog, Hamilton Sundstrand, Northrop Grumman

We also carry a broad inventory of Tiernay Metals parts, BAC Boeing profiles, LS Lockheed shapes, and AND drawings, with standard sizes available for fast quotes and rapid delivery.

Contact our sales team for a complete inventory list or a custom quotation. Quick Quote

Applications of aerospace aluminum extrusions

• Wing spars and main beams
• Keels, stringers, and longerons
• Landing gear struts
• Cockpit structural components
• Ailerons, elevators, and rudders
• Seat tracks and seat frame structures
• Interior components
• Avionics mounts and electronic housings
• Hollow beam-style rotating parts (e.g., helicopter components)
• Load-bearing fuselage and tail structures

Machining services we offer

Chalco specializes not only in aerospace-grade aluminum extrusions but also in providing one-stop precision machining and value-added services to help reduce lead times, lower costs, and improve project efficiency.

• Standard aerospace heat treatment processes to enhance material strength and stability
• High-precision sawing, grinding, and hot forming to ensure dimensional accuracy and surface quality
• Waterjet cutting for precise, heat-free shaping of complex parts
• Trepanning for accurate circular holes in tubing and hollow components
• In-house Haas VF-9 and VF-6 vertical mills for machining large 2024 and 7075 extrusions
• CNC milling for seat tracks, stringers, reinforcements, and other structural parts
• Support for SolidWorks and Mastercam CAD modeling, with full FAI reporting available

Quality control commitment

At Chalco, we are committed to aerospace standards and have established a comprehensive quality control system to ensure every aluminum extrusion meets the strict requirements of the aerospace and defense industries.

We apply advanced extrusion technology and strict process control, starting with incoming material inspection—checking surface condition, dimensions, mechanical properties, and certifications to ensure no scratches, dents, and full traceability between heat numbers and test reports.

Throughout production, we conduct visual inspections, dimensional checks, tensile and corrosion testing, and use CNC coordinate measuring machines (CMM) and automated inspection equipment to guarantee precision and consistency.

Our facilities are certified to both ISO 9001:2015 and AS9100:2016 Rev D, and we implement statistical process control (SPC) to maintain a PPM (parts per million) defect rate well below industry averages.

From small test batches to full-scale production, Chalco is dedicated to delivering zero-defect, high-quality aerospace-grade products you can trust.

Why choose us

• Integrated services: From design and extrusion to manufacturing and surface treatment, our experienced engineering team customizes each profile to your needs.
• Fast delivery: Low minimum order quantities with lead times as short as 2 weeks—ideal for urgent projects.
• Full support: One-on-one technical assistance from design consultation to after-sales service ensures smooth project execution.
• Diverse material options: Stock and custom supply of aerospace aluminum alloys such as 6061, 2024, and 7075 to meet various strength, weight, and corrosion requirements.
• Global reach: Whether you're in North America, Europe, Asia, or the Middle East, we provide fast response and worldwide delivery.
• Cost-effective: Competitive pricing without compromising quality or service.

Contact us today for a personalized quote or to learn more about our aerospace aluminum extrusion solutions—Chalco is your trusted partner in precision and performance. Quick Quote

Packaging and shipping

Proper packaging is essential for transporting aerospace extrusions. At Chalco, we understand the risks during transit and use high-standard packaging methods to minimize damage and reduce return rates.

• All profiles are inspected for dimensions and appearance before storage, ensuring no scratches or dents. Certification documents and heat numbers are verified against test reports.
• For profiles ≤ 6 feet in length, we use 0.180-inch thick rigid tube packaging.
• Longer profiles are packed in 5-inch or 4×8-inch flexible cartons made of dense cardboard panels with internal dividers—designed to accommodate various shapes including square, rectangular, L, U, and triangular sections.
• Every packaging solution is engineered for impact resistance, compression strength, and surface protection to ensure safe delivery.
• All orders are eligible for global shipping.

Chalco also offers other aircraft products

Aircraft aluminum sheet

In addition to extrusions, Chalco also stocks a wide range of aerospace sheets and plates.

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Aircraft aluminum sheet is available in a wide range of thicknesses from 0.011" to 5.000", with common customer selections including 0.032", 0.063", 0.125", 0.250", and 0.500" for both structural and skin applications. Quick Quote

Aerospace aluminum plates can be cut to size or from stocked remnants, and can also be cut in half or thirds for faster and more cost-effective shipping.

2024 Aircraft Aluminum Sheet Plate

7075 Aircraft Aluminum Plate

7050 Aircraft Aluminum Plate Sheet

Aerospace titanium

If you're looking for high-quality titanium tubing, bars, extrusions, sheets, and plates, Chalco is your ideal choice.

Click to view all of Chalco's aerospace titanium products.

Standard sheet size is 36″ x 96″, with cut-to-size options and stock remnants also available.

Available in thicknesses from 0.016″ to 0.125″, with popular sizes including 0.025″, 0.032″, 0.040″, 0.063″, and 0.090″.

Titanium tubing

Titanium bars

Titanium forgings

Stainless steel sheet & coil

Standard sheet size is 36″ x 120″, while standard coil size is 24″ wide with customizable lengths.

Available in thicknesses from 0.005″ to 0.125″, with popular sizes including 0.016″, 0.025″, 0.032″, 0.040″, and 0.063″ commonly used for aerospace skin and structural applications. Quick Quote

Aerospace fasteners

Chalco is recognized as an expert in aluminum and titanium aerospace fasteners, offering a wide range of stocked grades such as MS, BAC, NAS, and AN to help customers find the right solution for their aircraft.

All fasteners come with certificates of conformity and full traceability is available upon request.

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Washers

Cherry Rivets

Bolts

Nuts

Bolts

Sheet Metal Screws

Aircraft aluminum weight calculator

Want to quickly estimate the weight of aluminum profiles?

Use our aircraft aluminum weight calculator—just enter the dimensions online to get instant results.

Click the image or text below to open the aluminum weight calculator.

Aluminum sheet weight calculator

Aluminum bar weight calculator

Aluminum tube weight calculator

Frequently asked questions

What is extrusion in the aerospace industry?

Extrusion is a metal forming process where material is pushed or drawn through a die to create a desired cross-section. This method allows for the production of complex profile shapes.

What is the difference between extrusion and casting?

Casting is limited to low-melting-point metals like aluminum, magnesium, and copper. It has higher initial mold costs and shorter mold life.

Extrusion, with lower startup costs, is ideal for short-run production. Unlike castings, extrusions are less limited by size.

What is the difference between extrusion and rolling?

Extrusion allows for a wide variety of shapes, especially complex or continuous cross-sections, and offers flexibility in texture and finish customization.

Rolling produces flat sheets, either smooth or textured, and is best for uniform thickness.

What is the difference between drawing and extrusion?

Unlike extruded tubes and beams, drawn parts are pulled through a die multiple times to gradually reach the desired dimensions.

Extrusion pushes metal through a die in one pass, while drawing reduces the size with each pass until the final shape is achieved.

How to distinguish forging from extrusion?

Forging uses high pressure to shape irregular, high-strength parts.

Extrusion pushes metal through a die to create continuous profiles with consistent cross-sections.