Overview of T-Slot Aluminum Systems
T-slot aluminum profiles are widely used in industrial automation, workstations, machine frames, guarding systems, and modular structures. Their popularity comes from flexibility, reusability, and ease of assembly.
A key reason these systems are so versatile is the wide range of fasteners and accessories that can be used with them, allowing for endless customization and adaptation.
Made from high-quality aluminum alloys such as 6063-T5, these profiles offer excellent strength-to-weight ratios and corrosion resistance, making them suitable for both indoor and outdoor applications.
T-Slot Fasteners
Without a strong foundation, a structure will not last very long. The same can be said about T-slot framing and the fasteners that hold it together. Here are the main types of fasteners used in T-slot aluminum systems:
T-Nuts and Slot Nuts
T-nuts are the core fastening components in any T-slot aluminum system. They slide or drop into the profile slot and provide a threaded connection point for bolts and accessories.
- Standard slide-in T-nuts
- Drop-in (roll-in) T-nuts
- Spring-loaded T-nuts
- Hammer nuts
Available in thread sizes M4-M12 and materials like carbon steel, stainless steel, or alloy steel.
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Bolts and Screws
Bolts and screws connect brackets, plates, and accessories to T-nuts. The most commonly used types are:
- Hex socket head cap screws
- Button head screws for low-profile connections
- Flat head countersunk screws for flush mounting
Proper bolt length is important to ensure secure fastening without damaging the profile or nut.
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Corner Brackets
Corner brackets are used to create strong 90-degree or multi-angle joints between profiles. They improve structural rigidity and are ideal for frames, racks, and enclosures.
- Internal hidden connectors for clean aesthetics
- External corner brackets for heavy-duty applications
- Adjustable angle brackets for non-standard angles
Available in various sizes and materials to suit different load requirements.
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Joining Plates & Gussets
Joining plates and gusset plates are flat or reinforced connectors used to strengthen joints or connect profiles on the same plane.
T-slot gussets add extra support for strength to ensure a high-strength joint on 90-degree connections. These can be used alone or in addition to another fastening method for increased strength.
Commonly used in large frames, machine bases, and load-bearing structures.
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Universal Connectors
Universal connectors provide some adjustability for connections that are 90 degrees. This fastener is made up of a universal casting and a bolt.
Max strength can be achieved in one direction as well as a completely adjustable joint position with a drop-in t-nut.
Machining will be needed for this fastening method, but it offers excellent flexibility.
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Other Fastening Methods
Additional fastening methods to consider for your T-slot aluminum projects include:
- Anchor fasteners – great for durability and strength, vibration-proof
- End fasteners – durable with a clean aesthetic
- T-slot brackets – no machining required, ideal for time-sensitive projects
The right fastening method depends on your specific application, load requirements, and aesthetic preferences.
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T-Slot Accessories
The versatility of T-slot aluminum systems is greatly enhanced by the wide range of accessories available. These accessories allow for complete customization and functional adaptation:
Hinges & Pivot Joints
Hinges allow doors, panels, or covers to open and close smoothly. Pivot joints enable adjustable or rotating connections, often used in ergonomic workstations or adjustable equipment.
Materials include aluminum, steel, or zinc alloy, depending on load and environment.
View ProductsEnd Caps & Slot Covers
End caps close off the open ends of aluminum profiles, improving safety and appearance. Slot covers snap into unused T-slots to:
- Prevent dust and debris accumulation
- Improve aesthetics
- Protect cables or hands from sharp edges
Typically made from plastic, rubber, or PVC.
View ProductsFeet & Casters
For floor-standing structures, accessories such as:
- Adjustable leveling feet
- Fixed or swivel casters
- Heavy-duty base plates
These provide stability, mobility, and height adjustment for your structures.
View ProductsPanel Mounting
Panels made of acrylic, polycarbonate, metal, or wood can be mounted using:
- Panel clamps
- Slot-mounted panel holders
- Rubber strip inserts
Widely used in safety guarding, enclosures, and display systems.
View ProductsCable Management
Cable clips, cable holders, and wire ducts can be mounted directly into T-slots, keeping wiring organized and safe in automation and electrical applications.
Helps maintain a clean and professional appearance while protecting cables from damage.
View ProductsFunction-Integrated Profiles
Special profiles designed for specific functions:
- Cable-routing profiles for integrated wire management
- Ecoshape round tube system for “lean production”
- Linear guides for motion applications
These profiles offer enhanced functionality while maintaining the modularity of the system.
View ProductsCommon Applications
T-slot aluminum systems are used in a wide variety of applications across multiple industries. Here are some of the most common use cases:
Machine Frames
Strong, rigid structures for industrial machinery
Workstations
Ergonomic and customizable workbenches
Safety Guarding
Protective barriers and enclosures
Robot Cells
Frames and structures for robotic systems
Industrial Carts
Durable, mobile transport solutions
Shelving & Racks
Custom storage solutions
Jigs & Fixtures
Workholding solutions for manufacturing
Display Systems
Exhibition and retail displays
Material Specifications
Common Aluminum Alloys
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6063-T5: Excellent corrosion resistance, good formability, and weldability. Commonly used for standard applications.
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6061-T6: Higher strength than 6063, with good corrosion resistance. Ideal for heavy-duty applications.
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6005-T5: Similar to 6063 but with higher strength. Often used in structural applications.
Standard Profile Sizes
Metric Series:
- 20 series (20×20 mm)
- 25 series (25×25 mm)
- 30 series (30×30 mm)
- 40 series (40×40 mm)
- 45 series (45×45 mm)
- 60 series (60×60 mm)
- 80 series (80×80 mm)
Fractional Series:
- 10 series (1×1 inch)
- 15 series (1.5×1.5 inch)
- 20 series (2×2 inch)
Surface Treatments
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Anodizing: Creates a durable, corrosion-resistant finish. Available in clear, black, or other colors.
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Powder Coating: Provides a thick, durable finish in various colors.
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Electrophoretic Coating: Creates a smooth, uniform finish with excellent corrosion resistance.
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Brushing: Creates a textured, linear finish for aesthetic appeal.
Technical Properties
| Property | 6063-T5 | 6061-T6 |
|---|---|---|
| Yield Strength | 16,000 psi (110 MPa) | 35,000 psi (240 MPa) |
| Tensile Strength | 27,000 psi (190 MPa) | 45,000 psi (310 MPa) |
| Modulus of Elasticity | 10,000,000 psi (69 GPa) | 10,000,000 psi (69 GPa) |
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Have questions about T-slot aluminum systems or need help selecting the right fasteners and accessories for your project? Our team of experts is here to help.
