Aluminum box profiles are an essential element of many structural, architectural and industrial applications. Their hollow rectangular or square cross section provides strong yet lightweight corrosion-resistant support frameworks and enclosures. As a professional aluminum profile manufacturer, we offer both standard sizes of box sections as well as tailored solutions tailored specifically for each requirement. Below we introduce key dimensions, applications, selection criteria to assist buyers and engineers find their most appropriate rectangular aluminum profile section solution.
What Are Aluminum Box Profiles?
Aluminum box profiles, also known as aluminium box sections, are extruded profiles with square or rectangular hollow shapes. They are widely used because of their high strength-to-weight ratio, excellent corrosion resistance, and easy machinability. The profiles are typically made from 6061, 6063, or 6082 aluminum alloys, which offer good weldability, anodizing capability, and mechanical performance.
There are two primary types:
- Square box sections (e.g., 20×20, 50×50, 100×100 mm)
- Rectangular box sections (e.g., 40×20, 100×50, 200×100 mm)
Standard sizes are readily available, but manufacturers also provide custom profiles based on design drawings or specifications.
Common Standard Aluminum Box Section Sizes
Standardization in aluminum box section sizes offers significant benefits, including readily available stock, reduced lead times, and established compatibility with off-the-shelf connectors and fittings. These profiles are generally categorized by their outer dimensions, accommodating a spectrum of needs from lightweight frameworks to heavy-duty structural components.
We classify common sizes into three categories: Small, Medium, and Large Sections, each suited for distinct application requirements.
1. Small Sections (10mm – 40mm Outer Dimension)
These smaller profiles are ideal for applications where precision, lightweight construction, and subtle integration are paramount. Such as lightweight frameworks, enclosures, signage, and hobbyist structures. They offer sufficient strength for moderate loads without adding unnecessary bulk.
| Size (mm) / (inch) | Common Use Cases |
| 10mm, 15mm, 20mm | DIY projects, model frameworks, electronics casing |
| 25mm (1 inch) | Furniture framing, shelving supports |
| 30 x 30 mm | Sign stands, display racks |
| 40 x 20 mm, 40 x 40 mm | Retail displays, light-duty structures |
2. Medium Sections (40mm – 100mm Outer Dimension)
This category represents the workhorses of the aluminum box profile family. They strike an excellent balance between strength, weight, and ease of handling, making them incredibly popular across diverse industrial and commercial sectors. Common used in modular systems, interior partitions, machinery guards.
| Size (mm) | Common Use Cases |
| 50 x 20 mm, 50 x 25 mm | Panel supports, machine housings |
| 50 x 30 mm, 50 x 50 mm | Structural framing in equipment and furniture |
| 60 x 40 mm, 60 x 60 mm | Kiosks, instrument racks |
| 75 x 50 mm | Load-bearing mid-sized structures |
| 100 x 25 mm, 100 x 50 mm | Warehouse racking, partitions |
| 100mm, 75mm, 70mm | Equipment frames, gates |
3. Large Sections (100mm and Above Outer Dimension)
When significant structural support or large spans are required, these heavier-duty aluminum box profiles come into play, often used for heavy-duty structures such as trailers, construction frames, or architectural installations. They offer superior rigidity and load-bearing capacity while still maintaining the inherent benefits of aluminum over steel.
| Size (mm) | Common Use Cases |
| 100 x 100 mm | Structural beams in building projects |
| 150 x 50 mm, 150 x 150 mm | Bridge rails, transport platforms |
| 200 x 50 mm, 200 x 100 mm | Industrial support frames, modular buildings |
| 2 inch aluminium box | Construction, railing systems |
Each size offers varying wall thickness options based on the load and strength requirements. Wall thickness typically ranges from 1mm to 6mm depending on the application.
Custom Aluminum Box Profiles: Tailored Solutions
While standard aluminium rectangular box section sizes cover a broad range of needs, many projects demand a more precise, tailored approach. This is where custom aluminum box profiles become indispensable.
At CHAL, our expertise lies in transforming your design concepts into reality. Our customization include:
- Unique dimensions not covered in standard catalogs
- Specific wall thicknesses for strength optimization
- Anodized or powder-coated surfaces for corrosion resistance and aesthetics
- Pre-drilled holes or slots for assembly
- Special alloys for strength, marine, or aerospace applications
We work closely with our clients from concept to completion, ensuring that the final aluminium box profile not only meets but exceeds their expectations in terms of dimensional accuracy, surface finish, and mechanical properties. Feel free to email us for your special needs.
Choosing the Right Aluminum Box Profile Size for Your Project
Selecting the appropriate aluminum box section size is a crucial decision that impacts performance, cost, and overall project success. Consider the following factors when making your choice:
- Application Requirements: What is the primary function of the profile? Is it purely structural (load-bearing), aesthetic, or a combination? A load-bearing beam will require a larger, stronger profile (e.g., 150 x 50 aluminium box section) than a decorative trim.
- Load and Stress: Accurately assess the static and dynamic loads the profile will endure. This includes compressive, tensile, bending, and torsional forces. Engineers often calculate Moment of Inertia and Section Modulus to determine suitable dimensions.
- Environmental Conditions: Will the profile be exposed to moisture, chemicals, or extreme temperatures? While aluminum is inherently corrosion-resistant, specific alloys (like 6063 for better surface finish and corrosion resistance in architectural applications, versus 6061 for higher strength) and surface finishes (anodizing, powder coating) might be necessary.
- Dimensional Accuracy and Tolerances: Precision is paramount for complex assemblies. Standard extrusion tolerances are generally tight, but for highly sensitive applications, specify tighter custom tolerances.
- Fabrication and Assembly: Consider how the profiles will be cut, drilled, and joined. Larger, thicker profiles may require more substantial machinery for processing.
- Cost-Effectiveness: While custom profiles offer tailored solutions, standard sizes are often more economical for general applications due to higher production volumes. Evaluate the trade-off between customization benefits and potential cost implications.
- Aesthetics: The visual appeal of the profile, including its size, shape, and finish, should align with the overall design vision.
When in doubt, consult with a structural engineer or the aluminum profile supplier for recommendations based on your design specs.
Final Thoughts
Aluminum box profiles are a testament to the innovation and versatility of aluminum as a material. From intricate miniature components to robust industrial frameworks, their combination of strength, lightweight properties, corrosion resistance, and ease of fabrication makes them an indispensable choice across a myriad of industries. Whether you opt for a readily available standard aluminium rectangular box section or require a meticulously engineered custom solution, these profiles offer the reliability and design flexibility demanded by modern applications.
At CHAL, we pride ourselves on being a trusted partner for all your aluminum extrusion needs. With extensive experience in manufacturing a wide array of aluminum box section sizes, including popular dimensions like 50×50 aluminium box section, 40×40 aluminium box section, and larger profiles such as 200 x 100 aluminium box section, we are equipped to provide both high-quality standard products and precisely tailored custom solutions. Our team of experts is ready to assist you in selecting the ideal profile and alloy for your next project, ensuring optimal performance and cost-efficiency.
Contact CHAL today to discuss your aluminum box profile requirements and discover how our expertise can help bring your designs to life.
