Aluminum Square Tube Mold

Aluminum square tube is widely used in building curtain walls, mechanical frames, solar brackets, and vehicle structures, with high requirements for dimensional accuracy and appearance.

Chalco specializes in producing and stocking various extruded aluminum square tubes, with no mold fee, helping you save costs and shorten delivery time by 2–3 weeks. Custom sizes are available at wholesale prices, suitable for both small and large orders.

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We have 100+ sets of aluminum square tube molds, covering sizes from 12.7 × 12.7 mm to 200 × 200 mm, with wall thicknesses from 0.8–6.35 mm. Mold types include sharp-corner square tubes and round-corner square tubes, meeting different structural and decorative needs.

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Why choose existing molds?

In aluminum square tube production, customers can either use existing molds or opt for custom mold development. A comparison shows that existing molds are advantageous in most cases:

• Initial investment: Existing mold → No mold fee, lower cost; Custom → Requires mold fee, increasing budget.
• Delivery speed: Existing mold → Ready-made mold, fastest 7–10 days delivery; Custom → Requires mold making and testing, longer lead time.
• Size range: Existing mold → Covers common sizes from 12 × 12 mm to 200 × 200 mm; Custom → Any non-standard cross-section, fully produced according to drawings.
• Quality and risk: Existing mold → Mature molds, stable and reliable, with EN 10204 3.1 material certificate and test reports; Custom → New molds need debugging, with uncertainty.

If your needs fall within the standard size range, choosing existing molds is faster, more economical, and more reliable. For special cross-sections or unique designs, custom molds can be considered.

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Specifications of aluminum square tubes

Chalco's aluminum square tube products strictly comply with international and industry standards, ensuring that chemical composition, mechanical properties, dimensional tolerances, and processing requirements all meet customer expectations. Our products are widely used in aerospace, building structures, automobile manufacturing, and industrial equipment, providing customers with reliable quality assurance.

Aluminum square tubes specifications

Popular alloy types of aluminum square tubes

Aluminum square tube mold sizes

Aluminum square tube mold (Sharp Corner)

Sharp-corner aluminum square tube molds produce profiles with square shapes and sharp edges, suitable for frames and load-bearing structures that require high joining accuracy. They are commonly used in mechanical frames, curtain wall keels, and railings.

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The table below shows some common sharp-corner aluminum square tube mold sizes:

Aluminum square tube mold (Round Corner)

Round-corner aluminum square tube molds produce profiles with smooth edges and a user-friendly touch, reducing stress concentration and enhancing corrosion resistance. They are commonly used in furniture profiles, decorative structures, and outdoor frames.

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If you do not find a suitable size in the above mold size table, please contact our engineering team. We can provide custom mold solutions and fast quotation services.

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Tolerances for Aluminum Square Tubes

The dimensional tolerances of aluminum square tubes are closely related to the production process (extruded seamless / drawn seamless) and the measurement position (corner / non-corner).

Across flats (width/height)

• Extruded seamless: Tolerance range ±0.012″–±0.173″ (approx. ±0.30–4.40 mm), with stricter requirements at corners than non-corners.
• Drawn seamless: Tolerance range ±0.003″–±0.050″ (approx. ±0.08–1.27 mm), with significantly higher precision than extrusion.

Corner radius

• Sharp corners and small radius (<0.188″): Permissible deviation ±1/64″ (approx. ±0.40 mm).
• Large radius (≥0.188″): Permissible deviation ±10%.

Wall thickness

• Average wall thickness tolerance ±0.002″–±0.020″ (approx. ±0.05–0.51 mm).
• Maximum deviation at any point = fixed value or ±10% of average wall thickness, whichever is greater, and not less than ±0.003″ (0.076 mm).

Note:

Drawn square tubes offer the highest dimensional accuracy, making them suitable for applications with strict requirements on appearance and assembly. Extruded square tubes are more suitable for structural parts or general purposes. When selecting, customers should refer to specific tolerance values based on finished size range, process type, and whether the measurement is at the corner or non-corner position.

To view detailed dimensional tolerances for different processes and specifications, click to see the extruded seamless square tube tolerance table and the drawn seamless square tube tolerance table.

Aluminum square tube surface treatment and secondary processing

Common surface treatments

• 

  Anodizing forms a dense oxide layer, enhancing corrosion resistance and appearance. Common in curtain walls, decorative profiles, and transport interiors.

If you would like to learn more about process details and application cases, you can click to view our anodized aluminum tubes. 

Powder coating

• 

  Powder coating forms a durable, eco-friendly layer with strong adhesion and color stability, ideal for long-term outdoor use.

Wood grain transfer

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  Wood grain transfer gives aluminum a realistic wood look, combining light weight, durability, and low maintenance for doors, windows

Fabrication Options

• CNC machining: Slotting, drilling, chamfering, and milling for complex structures, with precision up to ±0.1 mm.
• Bending & welding: Custom frames, brackets, or assemblies per drawings, supporting MIG/TIG welding for stable structures.
• Cut-to-size: Flexible lengths from 100 mm samples to 6 m bars, suitable for prototyping and mass production.
• Assembly pre-treatment: Connectors and tapped holes can be pre-installed for quick assembly upon delivery, reducing on-site work.

Chalco aluminum square tube production capacity and equipment advantages

Chalco has strong equipment and production capacity, covering the full process from aluminum ingot smelting to extrusion and precision machining, meeting customer requirements for size, accuracy, and delivery.

• 50,000-ton vertical extrusion press: Produces large-diameter seamless aluminum tubes up to 1,320 mm in diameter, 200 mm wall thickness, and 12 m length—among the largest of its kind worldwide.
• High-precision extrusion and machining: For precision tubes, OD tolerance can reach ±0.05 mm and wall thickness tolerance ±0.1 mm, suitable for highly demanding structural or engineering applications.
• Production advantages: Large-scale capacity and equipment layout enable Chalco to supply common existing mold extrusions and support custom mass production.
• Integrated process: Casting → extrusion → machining → surface treatment, ensuring accuracy, reducing lead time, and improving logistics coordination.

Aluminum square tube pricing and stock supply

Looking for a reliable aluminum square tube supplier?

We keep regular stock and specialize in producing a wide range of square tubes, available in both metric and imperial sizes to meet diverse project needs.

• Pricing advantage: Prices depend on alloy grade, temper, surface finish, and order volume, with bulk orders offering better cost efficiency.
• Flexible supply: From small trial orders to large industrial volumes, available in cut-to-size or standard lengths.
• Molds and stock resources: Comprehensive mold library with some common sizes in stock for fast delivery.
• Global service: Export packaging, EN 10204 3.1 material certificates, RoHS/REACH compliance reports, and worldwide shipping support.

Contact us now to get a fast quotation, or click to view the latest stock list.

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Other aluminum tube products

Aluminum square tube FAQ

Can samples be provided?

Yes, we can provide short samples for testing and specification confirmation. Common alloys and sizes can be cut from stock, and special sizes can be machined as needed. Contact us to get free samples.

What is the minimum order quantity?

Common existing die sizes support small trial orders for prototyping or market testing. For custom dies or special alloys, the moq will be confirmed case by case.

How is the price calculated?

Price depends on alloy grade, temper (such as t5 or t6), size and wall thickness, surface finish, and order quantity. Larger orders are more cost-effective.

What is the typical lead time?

Existing die sizes can ship in as fast as 7–10 days. Custom dies typically require 3–5 weeks including die making, trial runs, and production.

What is the packaging method?

All aluminum square tubes use export-grade packaging that is scratch-resistant, moisture-proof, and impact-protected. Options include wooden crates, pallets, or banded bundles based on the shipping method. En 10204 3.1 material certificates and compliance documents are provided with the shipment.

Aluminum square tube tolerance table

Extruded seamless aluminum square tube tolerances

Notes:

• "At corner” = measured near the corner; "Non-corner” = measured at the mid-face.
• Non-corner tolerances do not apply in annealed temper (O temper) or when wall thickness is less than 2.5% of the overall dimension.
• Not applicable to special tempers such as T3510, T4510, or T6510.

Seamless drawn aluminum square tube tolerances

Width/height tolerances

Corner radius tolerances

Wall thickness tolerances (seamless drawn)

Notes:

In addition to the specified values, the deviation at any point must be ≤ ±10% of the average wall thickness, and not less than ±0.003″.

Hot-selling aluminum square tube stock list

Imperial sizes

Metric sizes