Product Line

Custom Aluminum
Extrusion Profiles

From initial concept and die design to prototyping, production, finishing, and fabrication — we bring your vision to life with precision engineering and end-to-end custom extrusion services.

Overview

Your Design, Our Expertise

At Yogi Extrusions, we specialize in transforming your unique design concepts into production-ready aluminum extrusion profiles. Our vertically integrated facility handles every step of the process in-house, from die engineering and metal flow simulation through extrusion, surface finishing, CNC fabrication, and final assembly.

Whether you need a single custom cross-section or a complete multi-component system, our engineering team works closely with you to optimize your design for manufacturability, performance, and cost-efficiency. With rapid prototyping in as few as 10 days, we help you move from idea to market faster than the competition.

What We Deliver

Custom die design with 3D metal flow simulation
Rapid prototyping and first article inspection
Multi-alloy options (6000, 7000 series and more)
Full finishing suite (anodize, powder coat, wood grain)
CNC machining, welding, bending, and assembly
Custom packaging and global logistics

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Capabilities

End-to-End Custom Solutions

Our vertically integrated facility and experienced engineering team deliver complete custom extrusion services under one roof.

In-House Die Design

Our experienced die engineers design and manufacture precision extrusion dies in-house, ensuring faster turnaround and tighter control over profile accuracy.

3D Metal Flow Simulation

Advanced FEA-based simulation software predicts metal flow, temperature distribution, and die deflection before cutting steel, eliminating costly trial-and-error.

Rapid Prototyping (10 Days)

From approved drawing to first article samples in as few as 10 business days, accelerating your product development cycle and time-to-market.

Multi-Alloy Options

Choose from a comprehensive range of alloys including 6063, 6061, 6005A, 6082, and 7075 series, each optimized for specific performance characteristics. See our Alloy Guide.

Full Finishing Suite

Complete in-house surface treatment capabilities including anodizing, powder coating, electrophoresis, wood grain, and mechanical finishes. Explore our Finish Options.

Value-Add Fabrication

CNC machining, punching, stamping, bending, welding, assembly, and kitting services transform raw extrusions into ready-to-install components.

Our Process

From Concept to Delivery

Our proven 6-step process ensures every custom profile meets your exact specifications while optimizing for manufacturability and cost.

Consultation & DFM Review

Our engineering team reviews your design requirements, application constraints, and performance criteria. We conduct a thorough Design for Manufacturability (DFM) analysis to identify opportunities for optimization.

We discuss alloy selection, tolerance requirements, surface finish options, and secondary fabrication needs to ensure the most cost-effective approach for your project.

Die Design & Simulation

Our in-house die engineers create precision die designs using advanced CAD/CAM software. We run 3D metal flow simulations to predict material behavior, optimize die geometry, and ensure uniform extrusion quality.

Simulation results guide bearing length adjustments, port bridge design, and pocket geometry to achieve the best possible profile accuracy and surface quality.

Prototype & First Article

We produce prototype extrusions and conduct comprehensive first article inspection (FAI) to verify dimensional accuracy, mechanical properties, and surface quality against your specifications.

Detailed inspection reports with CMM measurements, tensile test results, and surface finish verification are provided for your review and approval before proceeding to production.

Production Extrusion

Approved profiles move to full production on our high-tonnage extrusion presses. Real-time process monitoring ensures consistent billet temperature, extrusion speed, and quench rates for optimal metallurgical properties.

Our multiple extrusion lines accommodate a wide range of circle sizes and alloys, enabling flexible production scheduling and reliable on-time delivery.

Finishing & Fabrication

Extruded profiles receive the specified surface treatment and secondary fabrication operations. Our in-house capabilities include anodizing, powder coating, CNC machining (3-axis and 5-axis), punching, bending, welding, and assembly.

All finishing and fabrication processes are controlled under our ISO 9001-certified quality management system with full traceability from raw billet to finished part.

Quality Inspection & Shipping

Every production lot undergoes rigorous quality inspection including dimensional verification (CMM), mechanical testing, surface quality checks, and visual inspection against approved samples.

Finished products are carefully packaged with protective materials and shipped via our global logistics network. We offer flexible packaging options including custom crating, interleaving, and labeling to meet your receiving requirements.

Fabrication Services

Value-Add Capabilities

Transform raw extrusions into finished, ready-to-install components with our comprehensive in-house fabrication services.

CNC Machining (3-Axis, 5-Axis)

Precision milling, drilling, tapping, and pocketing on 3-axis and 5-axis CNC machining centers for complex feature creation and tight-tolerance requirements.

Punching & Stamping

High-speed CNC punching and progressive die stamping for holes, slots, notches, and complex patterns at production volumes.

Bending & Forming

CNC press brake bending, stretch bending, and roll forming capabilities for curved profiles, angles, and complex 3D shapes.

Welding (MIG, TIG, FSW)

Certified MIG and TIG welding for aluminum assemblies, plus friction stir welding (FSW) for high-integrity, distortion-free joints on critical components.

Assembly & Kitting

Multi-component assembly, hardware insertion, labeling, and kitting services to deliver complete, ready-to-install product assemblies.

Custom Packaging

Tailored packaging solutions including protective interleaving, custom crating, barcoding, and just-in-time delivery scheduling to match your production needs.

Custom AluminumExtrusion Profiles