Geometry and alloy
Profile weight per meter, cross-section complexity and wall thickness drive press speed and die life. Thin walls and large hollows slow production and raise scrap. Alloy choice compounds this: 6063 runs faster and finishes better; stronger alloys extrude more slowly.
- Weight per meter — the dominant material driver
- Wall thickness and thin-wall ratios
- Hollow vs. solid sections (die complexity)
- Circumscribing circle vs. press capacity
Tolerances and finishing
Tight tolerances on non-critical features cost money for no functional gain. Specify precision where fit demands it and standard tolerance classes elsewhere. Finishing adds process cost per meter — anodizing thickness classes and powder coat color/texture choices are the usual variables.
Volume and tooling
Setup and tooling cost is amortized across the run, so short runs carry a high per-piece burden. Custom dies are a one-time investment whose cost depends on size and complexity; how it is quoted (separate vs. amortized vs. waived) materially changes the comparison.
Logistics and packaging
Long, low-density profiles are freight-sensitive. Protective film, interleaving and custom packaging protect finish quality but add cost. For high-volume or cross-border programs, packaging and freight design deserves as much attention as piece price.