The use of state-of-the-art technologies

We not only supply complex profile cross-sections, but also all profile sizes currently feasible from a single source:

All profiles are produced at AFC using the most cost-effective machine within a carefully selected European extrusion network comprising 55 extrusion facilities. The process of selecting the most cost-effective facility for your product is a unique core competence of AFC’s engineers.

All key parameters are assessed, such as alloy, most cost-effective production, profile cross-section shape, technical, quality and visual requirements, packaging criteria, as well as logistical and, in particular, environmental requirements, right down to the delivery address. Our aim is always to achieve the best value for money for you.

The extrusion presses, with a wide range of pressing forces from 600 to 7,450 tonnes, are also equipped with a diverse range of specialised technological equipment (such as special cooling systems for high-strength profiles, etc.).

In addition to the standard aluminium alloys EN AW-6060 and EN AW-6063 for extruded profiles, we offer a total of 40 different alloys for a wide range of applications. The AFC alloy catalogue lists typical areas of application for the alloys as well as properties such as tensile strength and elongation at break:

Here is a quick overview of the most common alloys used in extruded products:

We would be happy to provide you with comprehensive advice to help you find the ideal alloy for your product or application.

With our low-carbon alloys REcycAL and ECOlogicAL, we offer you the opportunity to reduce the carbon footprint of your products and thus make a significant contribution to achieving climate targets.

*“Cradle-to-gate” calculation, life cycle assessment (LCA): A1–A3 modules, using the cut-off method, in accordance with ISO 14025 and EN 15804

Thermally insulated profiles are particularly suitable for use in the construction industry. The plastic insulating bars create a thermal break. This enables the structural requirements of modern architecture and energy-efficient construction to be met.

The sawing of extruded aluminium profiles is the first downstream process in the manufacture of high-quality aluminium components. Precise sawing is often a crucial prerequisite for the subsequent dimensional accuracy and optimal functionality of high-end products.

Our comprehensive sawing technology is based on high-precision, CNC-controlled machines that ensure precise cutting and minimal tolerances. Carbide and diamond saw blades guarantee the highest cutting quality. The use of the most efficient processes and maximum automation, combined with minimal waste, is essential for us to achieve competitive advantages.

Whether small, complex profiles or large, robust and very long components – we offer the right solution, even for particularly large profile cross-sections.

Almost every sawn or machined aluminium profile requires deburring – which is why deburring is a frequently used and essential step in the process.

At AFC, we use state-of-the-art technologies and precise methods to ensure that every profile meets the highest standards at the best possible price. Depending on requirements, we use both manual deburring methods and fully automated deburring machines with specially selected abrasives. These ensure the thorough removal of burrs and sharp edges. The precision applied is crucial for the functionality and aesthetic appearance of the end products.

We offer four different basic processes:

• Mechanical deburring – manual or machine-based using grinding, brushing or milling

• Trowalising – using special rotary vibrators and abrasive media made of glass, ceramic or plastic in various sizes and shapes

• Blasting – using sandblasting or glass bead blasting

• Chemical deburring – e.g. in an anodising pre-treatment bath or special chemical baths

Contact us to find the best method for your product!

Using state-of-the-art 3-axis and 5-axis CNC technology, we shape aluminium extruded profiles into their final form – precisely, efficiently and with consistent repeatability. The diverse range of machining centres within our comprehensive production network enables the highly complex machining of a wide variety of geometries and meets even the tightest tolerance specifications. Whether milling, drilling or thread cutting – thanks to consistent process reliability, we create bespoke solutions that meet the highest standards in technology and design.

The following processes are available:

• 5-axis CNC high-speed machining of small components

• 5-axis CNC machining of long profile sections up to approx. 20 m in length

• 5-axis CNC machining of bent profiles

• Precision CNC machining with the tightest tolerances

• Round bar machining on state-of-the-art turning centres

Specialised machining centres are available for large-scale production. Contact us – we will be happy to provide you with personalised and expert advice.

For larger quantities, punching is a particularly cost-effective and efficient method of processing aluminium profiles. The process is impressive not only for its low unit costs, but also for its high precision and clean finish.

Depending on your requirements, we offer tailor-made solutions:

• Short-length punching – precise machining of small profile sections

• Long-length punching – for profile lengths of up to 6 metres with fully automatic feed

The bending of aluminium profiles is an extremely complex process. Our engineers at AFC specialise in precisely and consistently bending or turning complex profile cross-sections in 2D and 3D. To successfully manufacture bent components from extruded profiles, precise coordination and consideration of the key factors throughout the entire production chain are essential. This ensures consistently high-quality and reliable deliveries. Our experts at AFC contribute this knowledge right from the early stages of product development to guarantee the success of your product from the outset.

Our bending capabilities include:

• 2D aluminium profile bending

• 3D aluminium profile bending

• Roll bending, mandrel bending, stretch bending, coiling

• Smallest possible bending radii

Laser processing of aluminium is used across a range of industries to manufacture components, prototypes, signs and various other products. This method is characterised by its high speed compared to other processes and enables the efficient processing of large quantities of material. Furthermore, the cutting process is extremely precise, leaves minimal residue and allows for the production of highly complex and detailed shapes and structures.

Waterjet cutting allows complex and precise contours to be produced with minimal effort.
We would be happy to advise you on selecting the most cost-effective processing method for your product.

Aluminium welding refers to the process of permanently joining aluminium parts by fusing the metals at the joint areas. This is achieved using heat generated by various welding processes.

We offer the following options:

• MIG or TIG welding

• FSW welding (friction stir welding)

• Laser welding

• Welding using welding robots

• In accordance with ISO 3834-2

• In accordance with EN 15085-2 for rail vehicle components

The screwing process is a crucial part of assembling sub-assemblies and structures that incorporate aluminium components. Screw fastening plays a vital role in ensuring the reliable and precise joining of components, which supports the stability and durability of your products.

The following types of screws are used:

• Screws

• Self-tapping screws

• Helicoil

• Press-fit nuts

The use of adhesives offers an effective, reliable and cost-effective method for joining aluminium components. This helps to enhance the performance and durability of products across various industries, whilst fully exploiting the advantages of aluminium as a material.

We can offer you the following processes:

• Bonding to your specific requirements

• Bonding of rail vehicle components in accordance with DIN 6701-2

We create a riveted joint by plastically deforming the rivet as it is pulled through a rivet die. Ideal for applications where a strong joint is required and where welding or other processes might generate too much heat or cause excessive material distortion. This method is particularly suitable for joining sheet metal and similarly thin materials.

Anodic oxidation – commonly known as anodising – is the most widely used process for surface finishing aluminium extruded profiles and components. Through controlled electrochemical conversion of the metal surface, a homogeneous, pore-free oxide layer is formed which bonds firmly to the base material and enhances the properties of the aluminium in several ways. Anodising offers a wide range of benefits:

+ It enhances the technically refined appearance typical of aluminium.
+ The surface is permanently protected against corrosion – ideal for outdoor use.
+ The anodised layer is hard, scratch-resistant and durable.
+ Electrical conductivity is prevented – an important aspect for many technical applications.
+ In its natural finish, the surface is fully recyclable, making it particularly resource-efficient.

At AFC, you benefit from a highly flexible range of services in the field of anodising technology:

• Pre-treatment processes in accordance with E0 to E7 for different gloss levels and textures

• Standard colours C0 to C35 as well as custom colours

• Design anodising for high-quality architectural or decorative applications

• Piece anodising for short parts from 5 mm to 4 m

• Bar anodising for long profiles up to 18 m

• Contact points sawn off on request or applied to internal surfaces / non-visible surfaces

• Coating thicknesses between 5 and 25 µm

• Hard anodised up to 450 HV for maximum wear resistance, with coating thicknesses up to approx. 50 µm and lengths up to 6,300 mm

• High-gloss anodised

• Internal anodised for technical or hygienic requirements in interior applications

• Compliance with various quality standards and specifications such as Qualanod or DIN 17611

Powder coating is a modern, highly environmentally friendly surface finishing process. Unlike traditional liquid paints, a dry powder coating is applied to the aluminium profile using an electrostatic process and then cured in an oven. This creates a dense, durable and decorative surface – ideal for both indoor and outdoor applications.

Through our high-performance production network, AFC offers you a wide range of powder coating technologies. In addition to highly automated vertical and horizontal coating systems for various profile geometries and lengths, we also have manual powder coating lines for special requirements. This enables us to cater individually to your technical, design and economic requirements.

An overview of our powder coating services:

• All RAL colours and custom colours (e.g. metallic, textured, matt, gloss)

• Horizontal coating for short parts and complex cross-sections

• Vertical coating for profiles up to 8m

• Special high-temperature-resistant coatings

• Standard coating thicknesses for indoor and outdoor use

• Custom coating thicknesses to technical specifications

• Precise masking of areas to be left uncoated or selectively coated

• Processing in accordance with internationally recognised standards such as Qualicoat, GSB, OFI, QIB

High-quality film coating of extruded aluminium profiles is far more than just temporary surface protection. It is an integral part of sophisticated logistics and finishing concepts – offering functional, aesthetic and economic benefits. At AFC, we ensure the flawless surface of your aluminium products throughout the entire value chain by applying protective or decorative films with precision.

Our comprehensive range of services in the field of foiling:

• Protective films for temporary surface protection during transport, storage or processing

• Decorative films in wood-effect, metallic finishes or custom designs for visual enhancement

• UV-resistant films for applications exposed to high levels of sunlight

• A selection of different adhesive strengths, tailored to surface texture and removability

• Fully automated or manual film application, depending on profile geometry and quantity

• Precise contour application even with complex profile cross-sections and visible surfaces

• Residue-free removal for flawless further processing or end use

For applications with specific design requirements or particular functional properties, liquid coating is a tried-and-tested and highly flexible solution for finishing extruded aluminium products. Unlike powder coating, the liquid coating process allows for the application of extremely fine, uniform layers of paint – including in special colours, high-gloss finishes or with customised physical properties.

Your benefits at a glance:

• Wide range of RAL, NCS, MUNSELL and custom colours – including metallic, pearlescent and special-effect finishes

• Wide range of RAL, NCS, MUNSELL and custom colours – including metallic, pearlescent and special-effect finishes

• Matte, semi-matt to high-gloss finishes, individually adjustable

• Application of special functional coating systems (e.g. conductive, chemical-resistant, UV-stabilised)

• Optimal results on visible surfaces with the highest demands on aesthetics and tactile feel

• Solvent- or water-based coating systems – tailored to environmental and process requirements

Using mechanical surface finishing processes such as blasting, grinding, brushing and tumbling, we finish aluminium extruded profiles precisely to your specifications. These processes not only create an ideal base for subsequent coatings, but also impart specific visual and tactile properties to the surface – ranging from a silk-matt finish to decorative textures.

An overview of our services:

• Sandblasting & glass bead blasting: Matting and cleaning with a defined surface texture

• Grinding: Removal of machining marks, targeted texturing

• Brushing: Decorative longitudinal or cross-hatch patterns for elegant finishes

• Trowalising: Deburring, smoothing and cleaning of small components

All processes are carefully tailored to the profile geometry, material and subsequent processing. This results in technical and design-oriented aluminium solutions with perfect surface quality – efficient, precise and sustainable.

Ready-to-install extruded products are given the finishing touch through printing for functional labelling, brand identification or decorative design – a process that is particularly popular in the electronics industry. We print your products exactly in accordance with your requirements and specifications:

Screen printing

Screen printing is ideal for flat or slightly curved surfaces and offers high opacity, colour brilliance and durability. Thanks to variable screen ruling, even the finest details, logos or technical markings can be produced to a consistent standard – abrasion-proof, UV-resistant and media-resistant.

Pad printing

Pad printing is used where traditional printing methods reach their limits: on curved, uneven or hard-to-reach surfaces. Using an elastic pad, the ink is transferred precisely to the surface – for razor-sharp results even with small font sizes and intricate designs.