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Custom Aluminum Extrusions in Illinois

From raw aluminum to assembled products, Hydro Extrusion can meet your design specs for custom aluminum extrusions in Illinois, and provide everything you need to go from design to production to just-in-time delivery of line-sequenced final product.

End shot of multiple extruded aluminum shapes

Hydro customers have access to unprecedented resources across our global business and North American network of 20+ plants with more than 60 extrusion presses. Utilizing both 6xxx series aluminum alloys and global access to proprietary alloys in the 1000, 2000, 3000, 5000 and 7000 series, we have the ability to satisfy your most complex size and shape requirements.

We offer the industry’s broadest product capabilities in press sizes and tonnages (direct and indirect extrusion), circle sizes, profile types and “green” billet. We are the only extruder that offers extruded profiles from .500" wide to 22.5", providing opportunities to create unique designs and next-generation shapes.

Aluminum extrusion profiles are integrated into a wide variety of products in many industries, including:

  • Transportation
    The light weight of aluminum makes it ideal for engine blocks, transmission housings, panels, roof rails and chassis of cars, boats, light and heavy-duty trucks, and railway and subway cars, as well as for the bodies and component parts of other vehicles. They are also in demand in the manufacture of more fuel-efficient and lighter weight automobiles, such as the new Ford F-150 pickup truck with its military grade, aluminum-alloy body and the Tesla Model S all-aluminum electric performance sedan.
  • Building & Construction
    Modern aluminum alloys can support heavy weights, and are ideal for structural components and frames. Aluminum weighs 35% to 65% less than steel while providing equal strength, and is used liberally for roofing, flashing, wall panels and spandrels. The metal is also a vital component of green/sustainable buildings, primarily for its recyclability. Extruded aluminum components resist distortion caused by weather and building movement, springing back from the shock of impact. Aluminum’s corrosion-resistant properties are another major asset, making it the preferred choice for construction in mining applications.
  • Appliances & Electronics
    In addition to its light weight, aluminum conducts heat efficiently, so the metal is commonly found in refrigerators, washers and dryers, HVAC equipment, condenser tubes, nuclear reactors, pharmaceutical thawing units, and in the heating and cooling devices of computers, audio/visual systems and electronics. Innovative designs by the engineering labs of Apple popularized aluminum laptop chassis, and the metal is used liberally in their iPod, iPad and iPhone products. Aluminum chassis are also invaluable for widescreen TVs, where a 50-pound 40-inch HDTV would weigh in at 100+ pounds if made from steel.
  • Packaging
    Packaging foil has grown steadily for decades and now serves three main categories - household/institutional foil, semi-rigid foil containers and flexible packaging. Innovative new technologies are allowing aluminum foil to be merged with flexible films to create packages that expand during production but contract as the product is consumed. More than 13 billion packages of coffee, soups, tuna, and pet food could benefit from this flexible packaging. The highly reflective characteristic of aluminum extrusions also make them useful for shielding products or areas from light, radio waves, or infrared radiation. 

Hydro's facilities in Connersville, Elkhart and North Liberty, Indiana, are fully equipped with a range of extrusion presses, including 1,675 ton (7"), 2,000 ton (9"), 3,600 ton (10"), 3,600 ton (12") and 6,000 ton (14", 16”), and supply all shapes, alloys and tempers, ranging in size from one millimeter to several feet long. Hydro North Liberty is capable of complicated hollow configurations and knurling for non-skid floor systems.

Hydro Sidney, in Ohio, is ISO 9001 certified and offers advanced aluminum fabrication and contract manufacturing services, state-of-the-art machining, fabrication and assembly services. Specialties include engineering assistance for product design, and semi and fully automated fabrication and assembly of complex sub-assemblies for transportation applications, dedicated work cells and production lines.

Wherever you are located in Illinois, Hydro can offer a full range of custom aluminum extrusions to meet every production requirement. Get in touch with us today to find out more.