In an era when aesthetics and energy efficiency are so important, aluminum proves to be unrivaled. It combines strength and resistance to external conditions with flexibility in design.

Thanks to its excellent mechanical properties, aluminum allows for the creation of slim, durable sliding structures (e.g. AS 178 HS MODERN with an ultra-thin 25 mm bar), window structures (e.g. AS 80 US) or pivot doors with non-standard dimensions (AS 100 Pivot). However, before the finished aluminum system reaches the customer, it has to go a long way. Let's take a closer look at the entire process.

1. Design and tools

Although machines and production halls are at the heart of aluminum profile manufacturing, the entire process begins much earlier at the designer's desk. It is at the concept stage that decisions are made that have a direct impact on every subsequent step: from pressing and CNC machining to the final assembly of the finished window or door system. The profile design is the result of a conscious combination of technical functionality, aesthetic requirements, and production capabilities. To achieve this, close cooperation between the design department, tool shop, production, and quality control is essential.

2. Extrusion of aluminum profiles

The mechanical process of manufacturing aluminum profiles begins with the delivery of specially selected cylindrical aluminum blocks to the extrusion department. Extrusion produces long, precisely formed elements, known as extrusions, which are later used in the production of systems.

Extrusion involves pushing heated material through a die – a mold with a pre-designed cross-section that defines the final shape of the profile. The temperature, pressure, and speed of the process must be precisely selected and strictly controlled to ensure high quality and the appropriate mechanical properties of the finished product. After leaving the mold, the profiles are immediately cooled, straightened, and cut to the specified lengths.

The origin of the raw material is also very important in the entire process. The aluminum alloys used must meet quality standards and be certified, because their purity and chemical composition determine the subsequent durability, corrosion resistance, and aesthetics of the surface.

3. Coatings and protection

After the extrusion step, aluminum profiles undergo a surface finishing process to give them the right protective and aesthetic properties. One of the most common methods is powder coating, which is done in specialized paint shops with automatic production lines. 

At Aluron, painting is carried out in accordance with the QUALICOATstandard, which guarantees durability, UV resistance, and uniformity of the coating. For applications in harsh climatic conditions, QUALICOAT SEASIDE is used, which offers increased resistance to corrosion and salt.

4. Prefabrication and CNC

After surface treatment, aluminum profiles are sent to the prefabrication department, where they undergo a series of mechanical operations to prepare them for the final step. This process involves activities such as cutting, milling, drilling, and punching holes, which are planned with great precision at the system design stage. The aim of this process is not only to obtain the right shape, but also to maintain full repeatability and compliance with technological assumptions.

Multi-axis CNC machining centers integrate multiple operations into a single, automated cycle. These machines allow for simultaneous cutting, drilling, and milling of profiles without the need to move them between stations, which significantly reduces production time and limits the risk of errors. Precision saws, punching presses, and automated feed tables support the entire process, increasing efficiency and allowing for the fulfillment of serial orders as well as more unusual, one-off projects.

5. What happens next with the profile?

Once the aluminum profile has undergone CNC machining and has been precisely cut, cleaned, and prepared for assembly, the stage of assembling the complete product begins. This is the moment when the individual components begin to form a coherent whole. Hooks, hinges, fittings, insulation inserts, and sealing systems are installed—all to ensure that the finished structure is airtight, durable, and resistant to changing weather conditions. This is where technical precision meets functional design.

Aluron has its own production line for manufacturing TPE seals from thermoplastic elastomer, which combines flexibility with high mechanical resistance. Seal sections not used during the production or assembly of window and door systems are processed on site. They are ground in special “mills” and prepared for reuse as part of the circular economy. The recovered material is reintroduced into the process as an additive to the primary raw material. This solution not only reduces waste and the consumption of natural resources, but also strengthens the plant's production independence. It allows it to make better use of its own resources and control the entire material cycle.

In the case of a hybrid system (ASH 80 HYBRID), the profiles are joined in an isomization process with a plastic core that fills the space between the aluminum elements, improving thermal and acoustic properties. In wood-aluminum systems, such as Gemini, aluminum profiles act as protective and decorative overlays, protecting the wooden or PVC part from the outside, which extends the durability and improves the aesthetics of the entire product.

The technological capabilities, such as bending curves, joining at individual angles, or even welding corners, make it possible to create structures that are perfectly suited to architectural needs. Gemini systems offer both crimped and welded corners, which allows for a smooth, uniform surface without visible profile joints.

Depending on the design, profiles can also be equipped with special polyamide spacers that ensure effective thermal separation between the outer and inner parts of the profile. In some systems (e.g., AS 75), anti-bi-metal spacers are also used to eliminate the effect of warping under the influence of temperature differences. Thanks to this, even large, non-standard structures remain stable, highly insulated, and durable for many years of use.

6. Quality control and certification

Before aluminum profiles and systems are launched on the market, they must undergo a series of specialized tests confirming their technical properties. The tests are carried out by independent domestic and foreign institutes, such as the Building Research Institute (ITB), the Ship Technology Center (CERTBUD), IFT Rosenheim, and the Passivhaus Institut in Darmstadt. Among other things, the thermal insulation, tightness, weather resistance, load-bearing capacity, and durability of the systems are tested. Thanks to certification, Aluron aluminum systems can be successfully used in energy-efficient and passive construction.

Importantly, Aluron tests not only individual profiles, but complete complex systems in real-life conditions. This means that the entire structure is tested: the frame, sash, glass, fittings, seals, and all mounting elements. As a result, the certificates and declarations of performance (DOP) ang. Declaration of Performanceobtained reflect the actual behavior of the system in the building.

Details create quality

The key advantage of modern aluminum joinery production is a comprehensive approach to the entire process, from system design, through pressing and machining, to painting and logistics. When all stages are integrated within a single production chain, it is possible to maintain full control over quality, high flexibility, and quick response to market needs.