Introduction to Aluminum CNC Machining
Aluminum is one of the most widely used materials in CNC machining due to its excellent strength-to-weight ratio, corrosion resistance, and machinability. It offers an ideal balance of mechanical properties, cost-effectiveness, and versatility—making it suitable for everything from lightweight prototypes to high-performance aerospace and automotive components. At Clarwe, we specialize in machining over 20 aluminum alloys, each selected for specific applications where precision, durability, and performance matter.
Key Advantages of Aluminum:
Aluminum Compared to Other Common CNC Materials
While materials like steel, titanium, and plastics each have their place in manufacturing, aluminum stands out for applications requiring a combination of lightness, strength, and manufacturability. Compared to stainless steel, aluminum is easier to machine, reducing production time and cost. Unlike plastics, it offers higher strength and temperature resistance. And versus titanium, aluminum provides a more cost-effective solution for non-extreme environments.
| Material | Strength | Weight | Machinability | Cost | Some Applications |
|---|---|---|---|---|---|
| Aluminum | High | Light | Excellent | $$ | Aerospace, automotive, prototypes |
| Stainless Steel | Very High | Heavy | Good | $$$ | Medical, food processing, high-stress parts |
| Titanium | Very High | Medium | Difficult | $$$$ | Aerospace, medical implants, high-temperature |
| Plastics | Medium | Light | Excellent | $ | Enclosures, wear-resistant parts, electrical insulation |
Aluminum Alloys: Properties and Applications
At Clarwe, we offer one of the industry's most comprehensive selections of aluminum alloys for CNC machining. Each alloy possesses unique characteristics that make it ideal for specific applications and environments. Our material experts help you select the perfect aluminum grade that balances performance, machinability, and cost-effectiveness for your project.
Common Aluminum Alloys & Their Characteristics
Aluminum 6061-T6/T651
The versatile workhorse. Excellent all-around mechanical properties, good weldability, and corrosion resistance. Ideal for structural components, automotive parts, and consumer products.
Aluminum 7075-T6/T651/T7351
The high-strength champion. Exceptional strength-to-weight ratio comparable to many steels. Perfect for aerospace components, high-stress applications, and defense industries.
Aluminum 5083-H111/H32
The marine specialist. Outstanding corrosion resistance in seawater and industrial environments. Excellent for shipbuilding, offshore platforms, and pressure vessels.
Aluminum 2024-T351
The aircraft aluminum. High strength and excellent fatigue resistance. Commonly used in aircraft structures, truck wheels, and structural applications.
Aluminum 5052-H32
The forming expert. Superior fatigue strength and excellent formability. Ideal for electronic chassis, marine applications, and sheet metal work.
Aluminum 6082/6082-T6/T651
The European standard. Similar to 6061 with improved strength characteristics. Excellent for transportation equipment, bridges, and crane components.
Aluminum 6063-T5/T6
The architectural beauty. Excellent extrudability and surface finish. Perfect for architectural applications, window frames, and irrigation systems.
Aluminum 7050
The aerospace solution. Superior stress corrosion cracking resistance. Used in thick aerospace components and military applications.
Aluminum 2017A
The machineable choice. Excellent machinability with good strength. Suitable for screw machine products and complex components.
Aluminum 2014/2014-T6
The strong performer. High strength and hardness. Ideal for heavy-duty forgings and aerospace structural components.
Aluminum Alloy Properties and Applications
| Aluminum Alloy & Temper | Tensile Strength (MPa) | Yield Strength (MPa) | Elongation (%) | Typical Applications | Machinability Rating |
|---|---|---|---|---|---|
| 6061-T6 | 310 | 276 | 12 | Structural components, marine fittings, automotive parts | Excellent |
| 7075-T6 | 572 | 503 | 11 | Aircraft parts, mold tools, high-stress applications | Good |
| 5083-H111 | 317 | 228 | 16 | Marine hardware, pressure vessels, offshore platforms | Good |
| 2024-T351 | 469 | 324 | 20 | Aircraft structures, truck wheels, hardware components | Fair |
| 5052-H32 | 228 | 193 | 12 | Electronic enclosures, marine fixtures, fuel tanks | Very Good |
| 6082-T6 | 340 | 280 | 10 | Transportation equipment, bridges, crane components | Excellent |
| 6063-T6 | 241 | 214 | 12 | Architectural extrusions, window frames, furniture | Excellent |
| 7050 | 510 | 455 | 10 | Aerospace components, defense applications | Good |
| 2017A | 425 | 275 | 15 | Screw machine products, automotive components | Excellent |
| 2014-T6 | 483 | 414 | 13 | Aerospace structures, heavy-duty forgings | Fair |
Choosing the Right Aluminum Alloy
Selecting the optimal aluminum grade depends on your specific requirements for strength, corrosion resistance, machinability, and cost. Our engineering team provides expert guidance during the quoting process to ensure you get the best material for your application. We consider factors such as:
CNC Machining Capabilities for Aluminum
At Clarwe, we leverage latest CNC technology to transform your aluminum designs into precision reality. Our extensive capabilities cover every major machining process, ensuring we can handle any project complexity, from simple prototypes to high-volume production runs with tight tolerances.
CNC Milling Services
Our multi-axis CNC milling centers deliver unmatched precision for aluminum parts. With 3-axis, 4-axis, and 5-axis machining capabilities, we create complex geometries, contours, and features that would be impossible with conventional machining. From rapid prototyping to production runs, we maintain exceptional accuracy across all aluminum grades.
- ⇒ 5-Axis Simultaneous Machining: Complex contours and deep cavities in a single setup
- ⇒ High-Speed Machining: Optimized cutting parameters for superior surface finishes
- ⇒ Large Capacity Machining: Handling parts up to 80" x 40" x 30" on our largest mills
- ⇒ Micro-Machining: Precision features down to 0.5mm with extreme accuracy
CNC Turning Services
Our CNC turning capabilities produce precision round parts with excellent concentricity and surface finishes. Using both standard and Swiss-style lathes, we deliver turned components that meet the most demanding specifications for roundness and tolerance requirements.
- ⇒ Multi-Axis Turning Centers: Complete complex parts in single operations
- ⇒ Live Tooling Capabilities: Mill and drill features during turning operations
- ⇒ Swiss-Style Precision: Ultra-precise turning for small, complex components
- ⇒ Secondary Operations: Comprehensive finishing and quality control
CNC EDM Services
For the most challenging aluminum components requiring extreme precision, our Electrical Discharge Machining (EDM) services deliver unmatched accuracy. We utilize both wire and sinker EDM to create complex features, sharp corners, and fine details in even the hardest aluminum alloys.
- ⇒ Wire EDM: Precision cutting with tolerances to ±0.0001"
- ⇒ Sinker EDM: Complex cavities and complex shapes
- ⇒ Small Hole EDM: Precision micro-holes as small as 0.3mm diameter
- ⇒ Custom Electrodes: Manufactured in-house for specific applications
Technical Specifications at a Glance
| Process | Tolerance Capability | Standard Lead Time | Max Part Size | Best For |
|---|---|---|---|---|
| CNC Milling | ±0.005mm | 2-3 days | 80" x 40" x 30" | Complex 3D shapes, contours, molds |
| CNC Turning | ±0.01mm | 3-5 days | Ø300mm x 500mm | Round parts, shafts, fittings |
| CNC EDM | ±0.002mm | 5-7 days | 400mm x 300mm x 200mm | Complex details, hard materials |
See Our Full CNC Capabilities | Request a Free Consultation | Explore Available Aluminum Alloys
Surface Finishing Options for Aluminum Parts
Transform your machined aluminum parts with our comprehensive range of surface finishing services. From enhancing appearance to improving functionality and durability, we provide the perfect finish to meet your project requirements and elevate the quality of your components.
Anodizing Services
Anodizing creates a durable, corrosion-resistant surface that can be dyed in various colors while maintaining aluminum's properties. Our anodizing services include:
• Type II (Sulfuric Acid) Anodizing: Standard corrosion protection with color options
• Type III (Hardcoat) Anodizing: Extra-thick coating for wear resistance
• Clear Anodizing: Maintains natural aluminum appearance with protection
• Color Anodizing: Available in black, red, blue, gold, and custom colors
Chemical Treatments
Specialized chemical processes that convert the aluminum surface for specific performance characteristics.
Our chemical treatments include:
• Chemical Film (Alodine/Chromate): Electrical conductivity with mild corrosion resistance
• Passivation: Removes free iron particles and improves corrosion resistance
• Electropolishing: Micro-smoothing for improved cleanliness and appearance
Paint & Coating Options
We offer various painting and coating solutions to provide both protection and visual appeal for your aluminum parts:
• Powder Coating: Durable, thick-layer protection with extensive color options
• Wet Spray Painting: Smooth, even coatings for precise color matching
• E-Coating: Electrophoretic coating for complete coverage including edges
• Ceramic Coating: High-temperature resistance for demanding applications
Mechanical Finishes
Enhance appearance and prepare surfaces for additional finishing with our mechanical options:
• Bead Blasting: Uniform matte finish that hides machining marks
• Brushing: Directional satin finish for aesthetic applications
• Polishing: Mirror-like reflective surface for decorative parts
• Tumbling: Deburring and edge-breaking for improved handling
Aluminum Surface Finishing
| Finish Type | Thickness | Hardness | Corrosion Resistance | Best Applications |
|---|---|---|---|---|
| Anodizing (Type II) | 0.0005-0.002" | 400-600 HV | Excellent | Consumer products, architectural components |
| Hard Anodizing | 0.002-0.004" | 500-700 HV | Superior | Military, aerospace, high-wear applications |
| Powder Coating | 0.002-0.004" | 3-4H Pencil | Excellent | Outdoor equipment, automotive parts |
| Chemical Film | 0.00001-0.00005" | N/A | Good | Electrical components, aerospace |
| Bead Blasting | N/A | N/A | Fair | Visual prototypes, consumer electronics |
Aluminum CNC Machining Applications by Industry
From prototyping to full-scale production, aluminum CNC machining serves as the backbone of innovation across industries. At Clarwe, we've partnered with engineers and designers to create precision components that meet the rigorous demands of these sectors.
Aerospace & Defense
The sky is no limit for our aluminum components. The exceptional strength-to-weight ratio of alloys like 7075 and 2024 make them ideal for critical aerospace applications where every gram counts but performance cannot be compromised.
• Aircraft structural components and brackets
• Satellite and drone housing and frames
• Defense system enclosures and mounts
• Avionics trays and communication equipment
• UAV components and landing gear parts
Automotive & Transportation
From concept cars to production vehicles, aluminum machining helps automotive innovators reduce weight while maintaining strength and durability. Our components help increase fuel efficiency and performance across the transportation sector.
• Engine components and transmission parts
• Custom brackets and mounting systems
• Electric vehicle battery enclosures and heat sinks
• Suspension components and steering system parts
• Prototype and concept vehicle components
Medical & Healthcare
Precision is paramount in medical applications, and our aluminum components meet the strictest tolerances required for life-saving equipment. We work with medical-grade alloys and finishes that meet regulatory requirements.
• Medical device housings and enclosures
• Surgical instrument components and handles
• Diagnostic equipment frames and mounts
• Laboratory equipment and research devices
• Portable medical device cases and carriers
Electronics & Technology
As devices get smaller and more powerful, our precision aluminum components provide the perfect blend of thermal management, EMI shielding, and sleek aesthetics that the tech industry demands.
• Heat sinks and thermal management systems
• Server racks and data center components
• Consumer electronics housings and bezels
• Robotics frames and actuator mounts
• Communication equipment and antenna components
Industrial & Manufacturing
Keep industry moving with durable, reliable aluminum components that withstand the rigors of daily operation in demanding environments. From factory automation to heavy equipment, we deliver parts that perform.
• Automation equipment and robotic end-effectors
• Machinery components and custom fittings
• Sensor mounts and enclosure systems
• Conveyor system parts and guides
• Tooling fixtures and production aids
Industry Applications
| Industry | Common Alloys | Key Requirements | Typical Components |
|---|---|---|---|
| Aerospace | 7075, 2024, 7050 | High strength-to-weight, tight tolerances | Structural brackets, aircraft fittings |
| Automotive | 6061, 5083, 5052 | Durability, heat resistance | Engine parts, EV battery trays |
| Medical | 6061, 2024, 5052 | Precision, cleanability, biocompatibility | Surgical tools, device housings |
| Electronics | 6061, 6063, 1050 | Thermal conductivity, EMI shielding | Heat sinks, server racks |
| Industrial | 6082, 2011, 6061 | Wear resistance, durability | Machine parts, conveyor components |
Quality Assurance and Certifications
At Clarwe, quality isn't just a step in our process—it's the foundation of everything we do. Our comprehensive quality management system ensures every aluminum part we machine meets the highest standards of precision, reliability, and compliance. From prototype to production, we deliver consistent quality you can trust.
| Certifications & Compliance |
ISO 9001:2015 Certified: Quality management system certification AS9100D Certified: Aerospace quality management system ISO 13485:2016 Certified: Medical device quality management NADCAP Accredited: Special processes accreditation for aerospace |
| Quality Control Processes |
First Article Inspection (FAIR): Comprehensive initial part validation In-Process Inspection: Real-time quality checks during production Final Inspection: Complete dimensional verification before shipment Statistical Process Control: Continuous monitoring of machining processes Documentation Package: Complete quality records with every order |
| Advanced Inspection Equipment |
Coordinate Measuring Machines (CMM): ±0.005mm accuracy for complex geometries Optical Comparators: 2D profile measurement and verification Surface Roughness Testers: Quantitative surface finish validation Digital Height Gauges: Precision vertical measurement capabilities Custom Fixturing: Part-specific inspection setups for complex components |
| Quality Documentation |
We provide comprehensive documentation with every order to ensure full traceability, compliance, and confidence throughout your supply chain. • Certificate of Conformity: Material and specification compliance • First Article Inspection Reports: Detailed initial part validation • Material Certifications: Mill test reports and traceability documentation • Inspection Reports: Complete dimensional validation data • Process Certifications: Special process documentation as required |
| Industry-Specific Compliance |
Our quality systems meet the strict requirements of regulated industries: • Aerospace: AS9102 FAIR, PPAP, and flight-critical documentation • Medical: USP Class VI, ISO 10993, and sterilization validation support • Automotive: PPAP levels 1–5, statistical process capability reporting • Defense: Source inspection support, DFARS compliance |
Quality Capabilities Overview
| Inspection Method | Accuracy Capability | Best For | Industry Applications |
|---|---|---|---|
| CMM Inspection | ±0.005mm | Complex 3D geometries, free-form surfaces | Aerospace, medical devices |
| Optical Measurement | ±0.002mm | 2D profiles, contour verification | Automotive, electronics |
| Surface Roughness | ±0.001μm | Surface finish validation | Medical, precision components |
| Hardness Testing | ±1% | Material property verification | Automotive, industrial |
| Visual Inspection | N/A | Cosmetic defects, surface quality | Consumer products, prototypes |
From raw material certification to final inspection, our quality assurance team ensures every aluminum part meets your exact requirements. We don't just measure parts—we build trust through consistent excellence and comprehensive documentation that gives you complete confidence in every component we deliver.
Get a Project Review | Contact Our Engineering Team | Request a Callback
Design Guidelines for Aluminum CNC Machining
Designing aluminum parts for CNC machining requires balancing functionality with manufacturability. Follow these expert guidelines to optimize your designs for better performance, faster production, and lower costs. Our engineering team is always available for free Design for Manufacturability (DFM) analysis before you place your order.
Key Design Considerations
- Wall Thickness: Maintain minimum 0.8mm wall thickness for stability
- Internal Corners: Use radius rather than sharp corners (recommended: 1/3 x cavity depth)
- Hole Depth: Limit through holes to 4x diameter, blind holes to 2x diameter
- Thread Depth: Design internal threads at least 2x hole diameter deep
- Text Engraving: Minimum 0.5mm character height with sans-serif fonts
- Tolerances: Specify critical dimensions only to avoid unnecessary costs
Standard Machining Tolerances
- Standard Machining:
±0.125mm (±0.005") - Precision Machining:
±0.025mm (±0.001") - High-Precision:
±0.0125mm (±0.0005") with special processes - Surface Finish:
Standard Ra 3.2μm,
fine machining Ra 0.8μm achievable
Recommended Design Parameters for Aluminum
| Feature Type | Recommended Value | Minimum Value | Design Tip |
|---|---|---|---|
| Wall Thickness | 1.5mm | 0.8mm | Use ribs for structural support on thin walls |
| Internal Corner Radius | 1/3 x cavity depth | 0.5mm | Larger radii allow faster machining |
| Hole Diameter | Standard drill sizes | 0.5mm | Depth ≤ 4x diameter for straight holes |
| Thread Size | M3 and larger | M2 | Avoid threading in deep blind holes |
| Text Engraving | 1mm character height | 0.5mm | Use simple, sans-serif fonts for clarity |
| Minimum Feature Size | 1.0mm | 0.5mm | Consider material strength for thin features |
Design for Manufacturing Tips
• Simplify Geometry: Reduce complex 3D contours when possible
• Standardize Features: Use standard hole sizes and thread types
• Avoid Deep Cavities: Design with accessible machining paths in mind
• Consider Material Grain: Orient critical features with material grain direction
• Minimize Setups: Design parts that can be machined in fewer orientations
• Add Chamfers: Include lead-in chamfers for holes and edges
• Group Tolerances: Keep tight tolerances only where absolutely necessary
Cost-Saving Design Strategies
• Reduce Machining Time: Minimize complex surfaces and deep pockets
• Optimize Material Usage: Design parts to fit standard stock sizes
• Avoid Special Tools: Use features that work with standard cutters
• Simplify Finishing: Specify surface finishes only where needed
• Combine Features: Design multi-functional features when possible
• Standardize Designs: Use common materials and finishes across projects
Design for Assembly Considerations
• Clearance Fits:
Allow 0.1mm clearance for press fits
• Assembly Access:
Ensure tools can access fastening points
• Alignment Features:
Include locating pins or alignment marks
• Serviceability:
Design for maintenance and disassembly
• Weight Reduction:
Use pockets and lightening holes where possible
Even if your design doesn't follow all these guidelines, our engineers can help optimize it for manufacturing. Upload your CAD files for a free DFM analysis and online quote to see how we can bring your aluminum parts to life with precision and efficiency.
Why Choose Clarwe for Aluminum CNC Machining?
When precision matters, engineers worldwide trust Clarwe for their mission-critical aluminum parts. We combine cutting-edge technology with human expertise to deliver results that generic quoting platforms simply can’t match. Here’s what sets us apart:
Aluminum Expertise
➤ 20+ Aluminum Alloys In-Stock: From 6061 to high-strength 7075 and marine-grade 5083
➤ Material Experts On Staff: Expert alloy recommendations for your application
➤ Same-Day Quoting: Engineers review files and provide quotes within hours
➤ Free DFM Analysis: Optimize your part for cost and performance
Precision You Can Trust
➤ Tight Tolerances to ±0.005mm with in-house CMM inspection
➤ First-Time Quality: 99.2% on-time delivery with full quality inspection
➤ AS9100 & ISO 13485 Certified: Meeting aerospace and medical standards
➤ In-House Quality Lab: CMM, optical comparators, surface roughness testers
The Clarwe Advantage: Engineer-Led Manufacturing
➤ Personal engineering oversight from quote to delivery
➤ Proactive solutions and expert guidance throughout your project
➤ Dedicated engineers act as an extension of your team
Clarwe vs The Competition
| Capability | Clarwe | Typical Machine Shops | Online Platforms |
|---|---|---|---|
| Engineering Support | Dedicated Engineer | Limited or Extra Cost | Automated Only |
| Quality Control | In-House CMM Inspection | Variable | Partner-Dependent |
| Material Options | 20+ Aluminum Alloys | 5-10 Standard Alloys | Limited Selection |
| Design Feedback | Free DFM Analysis | Often Additional Cost | Generic Suggestions |
| Certifications | AS9100, ISO 13485, ISO 9001 | Often Limited | Variable |
| Lead Time | 2-3 Day Prototyping | 1-2 Weeks | 3-5 Days |
Seamless Process, Perfect Results
➤ Online Quoting: Upload your CAD file for immediate pricing➤ Real-Time Project Tracking: Monitor your order with photo updates at every stage
➤ Comprehensive Documentation: Receive full inspection reports and material certs
➤ Dedicated Support: Single point of contact throughout your project
Global Capacity, Local Attention
➤ 520+ Manufacturing Partners: Global network with capacity for any project size➤ Risk-Free Sourcing: We manage quality across our entire partner network
➤ Scalable Production: From 1 prototype to 100,000+ production parts
➤ No Tooling Fees: Competitive pricing with no hidden costs
Join thousands of engineers who have made Clarwe their trusted manufacturing partner. Experience the difference that engineer-led manufacturing makes—upload your CAD files today for a free, no-obligation quote and detailed DFM analysis.
Frequently Asked Questions About Aluminum CNC Machining
| Application | Recommended Alloy | Alternative Options | Key Considerations |
|---|---|---|---|
| General Purpose | 6061-T6 | 6082, 6063 | Excellent machinability, good strength |
| High Strength | 7075-T6 | 2024, 7050 | Aerospace-grade strength |
| Marine Environment | 5083-H32 | 5052-H32 | Superior corrosion resistance |
| High Fatigue Resistance | 2024-T351 | 2014-T6 | Excellent fatigue properties |
| Forming/Blanking | 5052-H32 | 6063-T6 | Excellent formability |