When it comes to building frames, workstations, or structural supports, many people ask: “Is aluminium profile strong enough?” It’s a valid question—especially for applications involving load-bearing, motion systems, or industrial automation. In this blog, we’ll explore the strength of aluminium profiles, the factors that influence it, and how it compares to other materials like steel.
Understanding the Strength of Aluminium Profiles
The strength of aluminium profiles depends on several factors:
- Alloy type: Common alloys like 6061 and 6063 offer excellent mechanical properties. 6061-T6, for instance, has a tensile strength of up to 290 MPa, while 6063-T5 has around 190 MPa.
- Profile size and wall thickness: Larger cross-sections and thicker walls increase rigidity and load-bearing capacity.
- T-slot structure: The modular design adds strength through smart geometry. T-slot aluminium profiles can distribute forces more evenly than flat bar extrusions.
Load Capacity in Real-World Applications
T-slot aluminium profiles—also known as industrial aluminum extrusions—are widely used in factories and warehouses. They are strong enough to support:
- Workbenches holding over 300 kg
- Machine frames with high-vibration loads
- Automated conveyor systems
- 3D printer enclosures and CNC machine bases
- Simulator rigs with direct drive steering wheels and pedal force up to 100 kgf
For example, a 45×90 profile made of 6063-T6 alloy can carry static loads of over 800 kg in a vertical setup, depending on span and connection method.
Aluminium vs Steel: Strength-to-Weight Ratio
Steel is stronger by mass, but aluminium has a much better strength-to-weight ratio. In many applications, aluminium is strong enough while also being significantly lighter—about 1/3 the weight of steel.
This means:
- Easier assembly and transportation
- Reduced load on foundations and frames
- Better performance in dynamic systems (e.g., robotic arms)
So even if aluminium isn’t as dense as steel, it’s often the better choice for applications that require strength and flexibility.
Reinforcing Aluminium Profile Structures
If even more strength is required, aluminium profiles can be reinforced using:
- Double profiles or internal connectors for critical load points
- Steel brackets for high-torque mounting
- Cross beams to reduce bending under load
- Additionally, well-designed joints and quality fasteners (T-nuts, joining plates) play a major role in overall strength and safety.
Is Aluminium Profile Strong Enough?
Yes—aluminium profiles are strong, reliable, and widely trusted across industries. From lightweight frames to heavy-duty equipment enclosures, they offer an excellent combination of rigidity, modularity, and long-term durability.
At Shine Ground, we offer a wide range of 6063-T5 and 6061-T6 aluminium profiles tailored for structural use. Whether you’re designing a factory line, a cleanroom frame, or a racing simulator, we’ll help you choose the right profile strength for your project.
