How Aluminum Machining Benefits Your Project
Although some customers still call us “Accurate Plastics,” aluminum machining is the most common work in our shop every day. We handle 6061 aluminum parts so often that we keep it stocked by the ton.
From everyday brackets to aerospace components, aluminum makes it possible for us to meet just about any spec. In this guide, we’ll break down the grades we work with most and when each one is the right choice.
Our Deep Expertise in Aluminum Machining
There’s a reason aluminum keeps our machines busy. It cuts faster than steel, is strong without being heavy, and naturally resists corrosion. Even when the raw material costs more, the time saved in machining usually evens things out. In some cases, aluminum parts end up costing less overall than steel.
Aluminum is so popular, in part, because of its versatility. We use it for everything from tight-tolerance aerospace work to custom fixtures and formed assemblies. It machines cleanly, holds tolerances, and makes it possible to produce thin walls and complex shapes that would be tough to achieve in other metals.
Breaking Down the Aluminum Alloys
Not all aluminum is the same. Here are the grades we work with most often:
6061 Aluminum (6000 Series): This is the most versatile aluminum we stock. 6061 is a strong alloy that welds easily and machines beautifully, which is why it’s the go-to choice for structural parts and standard extrusions, such as angle, channel, and tube. It’s not ideal for cold forming or bending, but for fixtures, brackets, and general-purpose components, 6061 is a reliable, cost-effective choice.
5052 Aluminum (5000 Series): Thanks to its higher magnesium content, 5052 bends without stress cracking, making it our top pick now that we’re handle more sheet metal work in-house. It’s actually cheaper than 6061, welds just as easily, and is a great fit for formed assemblies, boat hulls, storage tanks, and other parts that need to flex without breaking.
7075 Aluminum (7000 Series): Zinc makes 7075 one of the strongest aluminum alloys you’ll find, which is why it shows up so often in aerospace. It’s noticeably heavier than 6061, machines slower, and costs more. However, when you need maximum strength with less weight than steel, 7075 is the clear choice. Nine times out of ten, when we cut 7075, it’s for high-stress or aerospace applications.
MIC-6 Cast Aluminum: MIC-6 is cast and stress-relieved, which gives it excellent flatness right off the shelf (approximately ±0.005" compared to ±0.030–0.040" for standard plate). It’s not strong enough for structural parts, but it shines in fixtures, base plates, and even rubber or plastic molds where dimensional stability is more important than brute strength.
Quick Reference: Choosing Your Aluminum Grade
| Grade | Cost Rank (Relative to Other Grades) | Machinability | Key Features |
|---|---|---|---|
| 5052 | $ | Easy | Bends without cracking |
| 6061 | $$ | Easy | Strong, reliable, weldable |
| 7075 | $$$ | Hard | Maximum strength-to-weight |
| MIC-6 | $$$$ | Moderate | Exceptional flatness & stability |
We stock the grades we use most and bring in the rest when a project calls for it. Because we’ve cut, bent, and finished them all, we know what works and what doesn’t. If you’re unsure which aluminum grade is right for your part, we’re happy to steer you in the right direction.
Common Aluminum Finishes
Here's something not everyone realizes: aluminum's shiny surface shows every tooling mark. While some customers appreciate the machined aesthetic, others prefer a cleaner appearance.
Depending on your needs, we offer multiple finishing options:
Anodizing for corrosion resistance and color
SuperBrushing for a uniform directional finish
Lapping for premium flat surface finishes
Just note your surface finish on the drawing. And if you’re not sure what’s best, we’ll help you choose an option that makes sense for your part and your budget.
Let's Talk About Your Next Aluminum Machining Project
Whether you need a one-off prototype or a production run of bent assemblies, we’ll help you select the most cost-effective material that meets your specifications.
Aluminum machining is happening in our shop all day, every day, and we’d love to show you why customers trust us with everything from simple brackets to complex aerospace components. Send us your CAD files and let’s discuss your next project.