How to order your cutting and tapping service online

If you don’t have the equipment to process your profile accurately, take advantage of our T Slot Aluminium cutting, drilling and tapping service. Just follow the steps in this article to get your project underway. Check out this blog on how to get the most out of your profile  

Design your project carefully

This is the most important step and will make or break your project before you make your first cut.

You don’t need an expensive CAD system, many of our customers have built amazing projects using a hand-drawn sketch. Just take your time and do this properly

If you find that your project is more complicated than you expected or even if you don’t have the time, we can take care of your design requirements.

We use Solidworks and can provide 3D models, bill of materials and IFC drawings.

Contact us for a free consultation.  

Cut your material.

Before you cut anything, make sure that you fully understand how to join T Slot Extrusions (did I mention that its important to design your project carefully)

Professional T Slot Aluminium cutting saw

Once you are confident that your cut list is correct you need to work out how much aluminium you are going to need. We strongly recommend that you use a cut list optimiser.

This will help you eliminate unnecessary wastage.

Use a new optimiser page for each size of the profile if you are ordering multiple sizes.

This will help you eliminate unnecessary wastage.

 

You can email a pdf copy of this list to us or just enter your requirements directly into the cut list form on our website.

Remember that the longer the profile the more expensive it is to transport. Usually, it is more cost-effective to cut the profile before delivering it. Once we know the delivery address and the length of the parcel we can provide a quote for delivery.  

 

Drill and tap your profile.

Machining T Slot Aluminium Profile

Drilling and tapping is the most time-consuming part of the project and requires the correct equipment in order to produce a high quality end product. In order to get this right we need as much accurate information as possible.if you have access to a CAD system we can use Solidworks models or step files to work out where you need the profile drilled or tapped. A simple hand-drawn sketch is usually all we need as long as it contains all the relevant dimensions we need. You can upload your drawings here on our tapping and drilling page.

If you need more information please see these useful pages for information about Extrusion taps, Fixing plates, Linear joints, Angular joints, Cube joints, Pawl clamps

 We provide a T Slot Aluminium cutting, drilling and tapping service.

 

 

T Slot Aluminium Profiles

Using aluminium composite panels in T slot builds.

T Slot Aluminium
Workbench Workstation

When you are building with T Slot extrusions, aluminium composite panels are a cost-effective way to enclose your structure. 

You can improve the rigidity of your structure or provide an airtight enclosure using composite panels in your build 

This is useful for building 

  • 3D printers 
  • Clean rooms
  • Cupboards
  • workstations
  • CNC machines 
  • Trolleys 
  • Exhibit display stands

Enclose the panels within the T slot or fix them to the external face using the T slot to hold the nuts required.

T slot Aluminium extrusion structure with composite panel walls

Composite panels can also be used to prevent access to areas where safety is a concern.

T Slot aluminium framed enclosure

Enclosure frame

Composite panels provide an excellent base for graphics and signs to be installed.

Including the panels at the design stage saves time when assembling your project.

Clear acrylic, aluminium sheet, plywood and a number of other materials can be used in the same way. 

If you have any questions regarding this please contact us 

Using aluminium composite panels in T slot builds. - aluminium extrusion

How to create a strong join in aluminium t-slot extrusion

We understand that you need to save time and money.  So we would like to show you the most cost-effective way to join extruded aluminium t-slot profile. 

Aluminium T Slot extrusion joint

This is the standard joining method for T Slot Aluminium profile and is surprisingly quick and easy.  In less than 60 seconds one can make a strong join between aluminium t-slot extrusions at a minimal cost.  There is no complicated machining involved.  There are no special tools required.  This can be done on-site without welding or the need for a hot work permit.  

Follow this step by step guide to learn how.

** For your own safety sake, please ensure that you follow all relevant safety procedures and guidelines when operating machinery and using power tools. **

T-Slot profile saw

1. Cut your profile to length.

It is important to make a clean accurate cut because this will impact the quality of your finished join.  Use a good quality saw with the correct type of blade for cutting aluminium.  A good supply of quality cutting fluid will be needed to prevent profile and blade overheating.  Make sure that your profile piece is securely clamped.  To save you time we are able to cut your aluminium profile to length for you.  You simply need to provide us with a cut list. 

T slot Aluminium extrusion drill and tap

2. Tap the core hole in the end to be joined.

This is a very simple and quick process as the core is perfectly formed to the correct size for tapping.  Use an M8 tap for slot 8 series, or M6 for slot 6 series, profiles.  Using an extrusion tap and the correct cutting paste will ensure a perfect thread will be formed.

GAP T Slot Aluminium drill jig

3. Drill an access hole for your hex key.

Use a drill press, or drill guide, to accurately position the hole and not damage the profile piece.  We generally use a drill press specially set up for this job.  The drill guide is only really useful for when you don’t have a drill press or when you’re on-site needing to drill a hole.  

T slot aluminium cap screw and washer for junction

4. Fit a low profile cap screw and washer to the hole you tapped earlier.

Aluminium profile system

5. Slide the washer and cap screw head into the slot.

Move it into the slot so that the cap screw lines up with the hole drilled earlier.

T Slot Aluminium Profile joining system

6. Using the access hole you drilled earlier tighten the cap screw with your hex key.

Make sure that the two sections of t-slot are perfectly aligned as you tighten up the join.

You have now created a strong join in aluminium t-slot extrusion.

There are several alternative methods of joining T Slot aluminium profiles.  These alternative methods are useful under different circumstances.  If you would like more information please check out our blog.  We have articles about through body joins and joins using clamping plates    

Check out this tutorial on how to make a standard connection in T Slot Aluminium.

T Slot Aluminium Extruded Profiles and accessories supplied by GAP Engineering in Queensland 

T-Slot Aluminium Profiles
Accessories for extruded T slot Aluminium Profile

How to keep up with the pace of change in the modern industrial environment.

You are probably aware that we are in the middle of the fourth industrial revolution.

The fourth industrial revolution is characterised by a fusion of technologies that is blurring the line between cyber and physical systems

The first three industrial revolutions transformed and revolutionised our society and with each stage the world fundamentally changed around us.  Technological evolution speeds up exponentially as each generation of technology improves on the last.  As change becomes more rapid it is becoming increasingly important to be aware of this when installing infrastructure such as factories.

There are some key areas where GAP Engineering can help improve your ability to keep pace.

CAD design 

Sliding Trolley

CAD models play a crucial role in the planning and implementation of modern factory installations.  It is becoming more common for the interior of entire buildings to be 3D scanned so that a complete CAD model of the entire workplace can be created.  Every detail such as work flow, positioning of safety fencing, height restrictions and positioning of equipment can be thoroughly analysed before any other steps are taken.

CAD models for all our profiles and accessories are available for download in several CAD formats.  If that is not of use to you, we provide a CAD design service.

To access our CAD files please complete this Confidentiality agreement  so that we can send you the CAD files you need.

For a copy of our latest catalogue please follow this link Alusic catalogue  

If you would like to talk to us about a project please follow this link  GAP Engineering  

Rapid prototyping 

How to keep up with the pace of change in the modern industrial environment. - aluminium extrusion

There’s an old saying, “The more things change the more they stay the same”.  So, keeping up with the changing industrial environment there will always be a need to convert new ideas into new physical functions.  That will normally require new machines.  To build new and better there will almost always be a need to build prototypes.  As the rate of change increases you would expect the pace of prototyping to increase correspondingly.

This is where products such as t-slot extruded aluminium profiles play a vital role in allowing for the construction of workable prototypes that can easily be redesigned and modified.  Furthermore using t-slot profile, many components can be recycled for other prototypes with minimal for cutting or welding of metal.  We stock over 60 varieties of t-slot profile as well as a large range of joining and other accessories.

Adaptable cost effective machine frames. 

How to keep up with the pace of change in the modern industrial environment. - aluminium extrusionHow to keep up with the pace of change in the modern industrial environment. - aluminium extrusion

Because it can be modified without the use of metal cutting, grinding, welding or painting the Alusic t-slot aluminium extrusion system can save a lot of money when there is a requirement for modifications and improvements to machine frames.  Because it is usually more cost effective to use this system for the initial construction it really is the best solution available. It is very easy to add additional components or frame work members with minimal impact.

Integration.

Steel engineering machine

Aluminium Profile conveyor system

How to keep up with the pace of change in the modern industrial environment. - aluminium extrusionHow to keep up with the pace of change in the modern industrial environment. - aluminium extrusion

Using T Slot Aluminium Profiles and accessories enables the smooth integration of many different components such as conveyors , workstations ,lighting,compressed air,electrical components and much more.When it is time to make some improvements it is easy to make modifications and add components.

Safety. 

Safety fence

The components that make up the framework we supply  match the safety fencing components so they can integrate perfectly and any modifications required can be carried out with minimal impact to the rest of the factory.

T Slot Aluminium Extrusions and accessories

GAP Engineering T Slot Aluminium Extrusions and accessories

Profilium T slot Aluminium Extrusions and accessories are used in the following applications.

    • Machinery Frames
    • Industrial work stations
    • Clean room work stations
    • Trade Show Displays
    • Conveyors
    • Clean Rooms / High Altitude Rooms
    • Display Units
    • 3D Scanning Frames
  • Linear Guides and Actuators
    • Machine Guards and Enclosures
    • Safety Fencing
    • Racing Simulators
    • Trolleys
    • Racks and Cabinets
    • Air Tables
    • Laboratory Jigs and Frames
    • CNC router beds and frames
  • Industrial Jigs
    • Robot Heads
    • Audio Visual Supports/ Frames
    • Special Purpose Vehicle frames
    • Automotive tie downs and roof racks
    • Light Boxes
    • Vision System frames
    • Camera stands
    • Automation Sensor Brackets
  • Solar panel stands/ supports

How to get the most out of your profile.

When you are spending your time and money on a project you need to be sure that you are getting the most out of your resources.

How to get the most out of your profile. - aluminium extrusion

Avoid wastage being a problem

Unintentional wastage can end up costing you a lot.  So, you need to plan carefully to avoid blowing your budget.  The last thing you want to see at the end of a job is a big pile of unused or incorrectly processed material.  spending some time planning your job and will vastly improve your chances of a great result.

T-Slot Extruded Aluminium Profile
Sample of extruded aluminium off-cuts

design your project thoroughly before you start cutting

If your project is relatively complex and you don’t have access to a CAD drawing system consider employing the services of a CAD designer. Planning your project properly will greatly increase the quality of your project and reduce the overall cost. Planning includes drawing up an optimised cutting list

Optimise your cutting list

Failure to do a thorough optimised cutting list is almost guaranteed to result in excessive wastage.

When you have a large number of pieces to cut, it can become very complicated calculating an optimised cutting list it.  Fortunately, there are a few free, and online resources available to help you out. 

For example, a quick web search found Cut list optimiser which is suitable for 1D bar optimisation.  The web site requires that you sign up to a free account so that you can save your projects for later review.  Before deciding to sign up, you can look at one of their demo’s or go straight to their offline project page.

Obligatory disclaimer:  Please note that we do not recommend any particular solution in preference to any other.  You are free to choose what suits you.  You can even create your own spreadsheet to assist you in your calculations.

Once you have your cutting list, you can send us a copy so that we can accurately cut it for you.  We can also arrange delivery if you need.  Please note that delivery costs vary considerably depending on size, weight, and delivery address.  The most expensive being full 6m lengths.

Cutting, drilling and tapping

Ensure that you use a very good quality saw that is specifically configured to cut aluminium .

Cut lengths that are inaccurate or not completely square will prevent you from achieving the best possible results.

Use an extrusion tap to create the threaded ends as well as a quality tapping gel that is formulated to cut aluminium. An extrusion tap differs from a regular tap in that it does not remove any material in the process and also hardens the surface of the thread. this results in a stronger thread and consequently a more reliable end product . Also, ensure that your taps are perfectly aligned to the core centre of the extrusion.

When drilling through the centre of the extrusion use a drill press or drilling guide to ensure that your holes are accurate and that your drill does not damage the edge of the slot.

T-Slot profile saw
T-Slot aluminium profile saw

Ask for advice

There are several options when in comes to connecting T slot profiles and the cost varies considerably . Ask us to show you how the various connection methods work and to explain the pros and cons of each option.

There are also several pitfalls to be aware of when assembling projects and we can help you save time (money) by sharing our experience with you

In addition to cutting, we can also drill and tap each piece of profile as needed if you require.

For more information on how to join our profiles please see these resources: Standard connection and Creating a strong join


We have produced this video tutorial to help explain the cutting drilling and taping process

GAP Engineering-Queensland’s supplier of T Slot Aluminium and accessories

Favicon

Safety around machinery

When it comes to work place health and safety, there are no compromises or short cuts.  Situations often occur where you need to review your machine guards and safety fencing.  These reviews sometimes lead to changes being necessary.

The Alusic t-slot aluminium machine guard and safety fencing system is fast, easy, and cost effective when changes or improvements are necessary.

For example, to free up some factory floor space, one of our customers moved a machine closer to another piece of moving equipment.  One result of this was that a safety audit had to be undertaken.  The final audit required that the guard fence around the relocated machine had to be increased in height.

machine guarding and safety fencing

The simplest, quickest, and most cost effective solution we came up with, was to replace the fence end posts.  The new posts had to be tall enough to achieve the required new fence height.  Then, new safety fence panels had to be bolted along the top.

We started building the new panels by adding a new rail along the top of each run of the existing fence.  This rail would become a common bottom for each of the new panels.

Aluminium safety fencing machine guarding

Next, intermediate posts, above the existing intermediate posts had to be fitted on the top of the fence.  These were made by cutting up the original fence end posts.  It was then simply a matter of fitting them to the new rail, above the existing posts, using clamping plates (084.308.003).

4040 T slot clamping plates extrusion accessories

After that, the panels proper were cut to size from 50 x 50 x 3 square galvanised steel mesh.  They were then slid into the t-slot framework we had constructed along the top of each fence run.  The whole new fence was then finished off with new top rails bolted down to each of the posts.

4040 T Slot Aluminium Extrusions

After working out what was needed, the whole exercise was carried out in only four hours with minimal impact to operations and personnel.

Because we re-used the original fence end posts the materials cost was kept to a minimum.  Also, there was no hot work required on site, and therefore no need for hot work permits or the associated paper work involved.  On completion of the work there was no requirement for painting or other surface treatment works and hence minimal clean-up costs.  These issues together helped minimise time and labour costs.

Most importantly of all, the goal of ensuring a safe environment, from a work place health and safety point of view, was quickly, easily, and economically achieved.

The fact that we could make use of the original fence end posts, and complete all the work in such a short time, is another demonstration of just how versatile and cost effective t-slot aluminium extrusions and accessories are for these types of projects.

T-Slot Aluminium Extrusions and Accessories

GAP Engineering T-Slot Aluminium Extrusions and Accessories

Conveyor systems

T-Slot Aluminium Profile Conveyor Systems Conveyor systems - aluminium extrusion

Conveyor systems - aluminium extrusion

Conveyor systems - aluminium extrusion

When you require a conveyor system you need to consider a lot more than just the conveyor itself.

These are some of the factors you may need to take into consideration

    • How you are going to integrate a conveyor system into your current infrastructure
    • How can ensure that it is safe to operate
    • How can you minimise disruption to your production while it is installed.
    • How easily can you make modifications to it.

Our extensive range of t-slot extrusions and accessories will help you to overcome these and many other challenges.

Because our products are so versatile and adaptable you will be able to design and construct your conveyor system and any associated equipment such as work stations or guarding out of the same easily integrated components

We can supply you with the CAD files you need to help you design your conveyor system or if you don’t have the design capability we can design a system for you.

We can supply the components you need and assist you in getting your system constructed in the best methods.

The Alusic range of conveyor belts is divided into eight broad groups:

– Series 20: belt conveyor with 20 mm roller for 18.5 mm profiles
– Series 30: belt conveyor with 30 mm roller for 356.001.028 and 356.001.032 profiles
– Series 1000: belt conveyor with 50 mm rubberised roller for 356.001.032 profile
– Series 50: belt conveyor with 50 mm roller for 45 mm profiles
– Series 95: belt conveyor with 95 mm roller for 90 mm profiles
– Series 2000: tab chain conveyor, fixed width of 82.5 – 114.3 – 190.5 – 254.0 – 304.8 mm
– Series 3000: modular chain conveyor, fixed width of 152 – 250 mm
– Pallet series: conveyor belt for 112.101.001 profile

with the series 50 and 95 being the most popular

T Slot Aluminium conveyor system

Inclined Conveyor

You can access resources such as CAD files , parts catalogues and guides on how to use these products here  Aluminium Profile Resources

Why are t-slot aluminium extruded profiles so popular?

T-Slot aluminium extruded profiles are popular for a variety of reasons. Mainly their popularity is due to them being lightweight and durable, and because they are basically modular components, that provide effective solutions for a variety of applications.

Compared with steel fabrication, a t-slot aluminium extruded profile doesn’t need to be welded, ground, primed or painted, saving both time and money in its manufacture. The practicality of a t slot profile makes them suitable for many manufacturing processes, including assembly, linear motion systems and automation.

Structural aluminium framing using a t slot profile has achieved great success and is regularly used in machine bases, laser enclosures, work stations, noise containment enclosures, and machine guard safety enclosures. Aerospace, medical device manufacturers and the electric vehicle industry, all make use of t slot aluminium extrusion profiles in their assembly and manufacturing processes.

Some of the benefits of t slot aluminum extrusion vs steel include:

  • An equivalent steel structure takes longer to engineer and assemble than aluminium.
  • Steel requires ongoing maintenance, because it’s prone to rust and corrosion, so it needs to be inspected and painted regularly to maintain its integrity.
  • Steel needs to be welded and ground whilst aluminium doesn’t.
  • Design changes can be made on the fly with t slot aluminium extruded profiles, whilst steel takes much more time to modify, meaning less delays and fewer missed deadlines.
  • Structural aluminium can be engineered much more precisely than steel with near perfect measurements, easily meeting compliance standards quickly and easily.

The need for low cost producers in a competitive market is vital for the Australian economy. So it is good to know that the need for modular custom and off-the-shelf t slot aluminium extruded profiles continues to grow, as more and more industries realise the benefits of using this lightweight and cost-effective material for their engineering applications.

A t slot profile made from aluminium is ideal for complex processes with multiple modular components, being cheaper and faster to produce, assemble and test than steel equivalents. The bottom line is that t slot aluminium extrusion profiles are just as strong as steel, whilst being faster to engineer and assemble, and cheaper and easier to maintain.

For more information on using t slot aluminium extrusion profiles for your applications, call us on 07 3823 1079 or send us an email.

T-Slot extruded aluminium profile joints – sliding clamp

Profile Joints – Part 6

Sliding clamp

In this, our sixth in a series of posts on aluminium profile joints, we talk about a sliding clamp. Although not strictly an Alusic product or a joint type, it is something we developed to use with the Alusic range of extruded aluminium profiles.

Imagine that you have machine frame constructed using aluminium extrusion, and you need a stop for some part of the machine’s function. Now imagine that you need to move that stop on a semi regular basis (eg: a number of times a day). It would be nice to be able to just grab a handle, release the stop, slide it to a new position, and clamp the stop in place. No need to go looking for a spanner or a hex key to undo clamping bolts, etc. etc..

Well, we have just the thing. At least we think we do. You’re free to decide for yourself.

sliding clamp

Sliding clamp

The concept works with any t-slot extruded aluminium profile. In this example we are using an M8x45* lobed knob (1077.36), an M8x25 rectangular nut (084.302.011), a length of 3 slot 40×40 extruded profile (084.102.005), and a piece of 50x50x5 square hollow section.

The crux of the concept though, is the lobed knob and the rectangular nut in the t-slot.  The rectangular nut readily slides in the t-slot of the profile until the knob thread is tightened. Even hand tightening the knob provides enough grip to very effectively clamp the slider in place.

sliding clamp

Lobed knob and rectangular nut

sliding clamp

Sliding clamp assembly

Slider options

The slider component need not be a hollow section like we’ve used in this example. The hollow section is ideal if your application calls for something like a telescoping arm or leg.  The slider could just as easily be a piece of angle as shown below.

sliding clamp

Optional use of angle as slider

One example of an ideal use case for a sliding clamp is as a movable stop on our Portable Saw Bench.  If you already have a saw bench, retro-fitting a sliding stop could be as simple as bolting a length of t-slot profile to your bench.  For example, 18.5×32 (084.101.003) has a single 8mm slot perfect for a rectangular nut.

T-Slot extruded aluminium profile joints – sliding clamp - aluminium extrusionT-Slot extruded aluminium profile joints – sliding clamp - aluminium extrusion

If you want a copy of the Alusic catalogue to view on your own PC, go to our site main page, fill in your name and email address and click the Send button. We will then send you an email with a download link for the PDF file.

T-Slot extruded aluminium profile joints – pawl clamp

Profile Joints – Part 5

Pawl clamp

In this post the focus is on the pawl clamping connector fastener, or ‘pawl clamp’ for short.  This is the fifth in our series of posts on aluminium profile joints.

pawl clamp

Pawl clamping connecting fastener

A joint constructed using a pawl clamp can have the relocatable advantage of a fixing plate, but via a single fixing screw rather than two. This means less stuffing about on those occasions when a joint needs to be moved.

Adaptable

The Alusic catalogue shows a pawl clamp for almost any joint type your application might require. The basic pawl clamp can be used in place of the standard connection to make a simple square joint, whether T or corner.

There are also pawl clamps that can be used to join profile pieces end-to-end, at an angle or straight, as shown in the diagram below.  This type of joint is stronger than the simpler linear joint or angular joint.  As a result, it can be used to construct a joint that can carry a bigger load, in tension, than a linear joint.

pawl clamp

Preparing the joint

Preparing the joint simply involves machining a hole of the correct diameter and depth in the first of the profiles to be joined.

pawl clamp

Ready for assembly

pawl clamp

Joint partly assembled

Assembling the joint

We can use two pawl clamps to join an 18.5×90 (084.101.006) to almost any profile with an 8mm t-slot. In this example we show it joined to an 18.5×32 , a 1 slot 40×40 , and a 6 slot 45×90

Start by putting the pawl(s) into the hole(s) machined in the first of the profiles to be joined.

The joint is completed simply by sliding the pawl clamp square nuts into the t-slot of the second of the profiles to be joined. When the required joint location is reached, simply use a hex key to tighten the fixing screws in place.

pawl clamp

18.5×90 joined to 18.5×32

pawl clamp

18.5×90 joined to 40×40

pawl clamp

18.5×90 joined to 45×90

So there you have it.  The pawl clamp; used to construct strong joints in extruded aluminium profiles, can be adapted to a variety of different joining requirements. The pawl clamp is so adaptable that it could readily be used in applications outside the realm of aluminium extrusions.  Use your imagination, almost any joint requirement can be fulfilled using pawl clamps.

If you want a copy of the Alusic catalogue to peruse on your PC, go to our site main page.  There is a place where you can enter your email address and click the Send button. We will then send you an email with a download link for the PDF file.

T-Slot extruded aluminium profile joints – Linear joints

Profile Joints – Part 3

Linear joint.

This is the third in our series of posts on aluminium profile joints.  In this one we focus on the linear joint.

A few months ago, we had a customer who was building a display stand to use at various trade shows around the country. The interesting things about this stand were a) the finished height needed to be changeable, b) it needed to be quickly and easily assembled and dismantled, and, c) it needed to be readily packed up for transport to and from venues.

Complying with c) was easy. Extruded aluminium profiles are readily amenable to being stacked and tied down to a pallet for easy handling and transport.

To make the thing quickly and easily assembled and dismantled (requirement b), we decided to use clamping plates for most of the joints. See this blog entry for more information about using clamping plates.

The reason for the changeable height was that some of the venues for these trade shows don’t have the ceiling clearance for their particular rather tall display stand. So we decided to make the top section in two parts. One of which could be left out of the assembly when ceiling height decreed.

Now, there are a number of methods to join aluminium profiles end to end. On this occasion though, the customer wanted to maintain the clean neat lines of the aluminium extrusion.  As a result, we elected to use linear joints in this case.

The linear joint is ideal when the joint is under a compressive axial load, as was the case here.  This joint type is not recommended for high bending load applications such as the middle of a long span beam.

T-Slot extruded aluminium profile joints – Linear joints - aluminium extrusion

As you can see in the diagram above, the joint piece(s) fit neatly inside the t-slot in the extrusion and there are no parts extending beyond the perimeter of the profile.  This diagram shows a 90mm version in the slot 8 series 40 x 40 profile.  The number of linear joint pieces used in any given joint is limited by the number of t-slots in the extrusions being joined.  The number actually used depends more on the strength and rigidity of the joint required.  In many cases, only one or two linear joint pieces are used even though there may be four or even six t-slots in the extrusions.

Joint construction.

T-Slot extruded aluminium profile joints – Linear joints - aluminium extrusion

Linear joint ready for assembly

T-Slot extruded aluminium profile joints – Linear joints - aluminium extrusion

Linear joint partly assembled

T-Slot extruded aluminium profile joints – Linear joints - aluminium extrusion

Linear joint completed

The linear joint is completed by pushing the ends of the extrusions to be joined firmly together, then tightening the grub screws so that their flat ends bare down on the bottom of the t-slot.  This holds the joint piece(s) firmly in place and the two extrusions cleanly together.

T-Slot extruded aluminium profile joints – Linear joints - aluminium extrusion

Linear joint – 90mm & 180mm

Linear joints are available in a number of different sizes for the slot 6, slot 8, and slot 10 series of Alusic extruded aluminium profiles.  Also, they are available in anodised aluminium, zinc plated steel, and stainless steel.

T-Slot extruded aluminium profile joints – Standard connection

Standard Connection

The standard connection is the simplest and most cost effective joint for Alusic aluminium T slot profiles.  It is a perpendicular (or square) joint using a single socket head screw (fixing screw) without the use of any fancy accessories.

In this simple joint the central hole in the first profile piece to be joined has a thread tapped into it.  The thread -diameter & depth- is to suit the fixing screw being used.  In the second profile piece, a hole is drilled perpendicularly through at the desired location of the joint.  The hole is to allow a hex key access to tighten the fixing screw.

T-Slot extruded aluminium profile joints - Standard connection - aluminium extrusion

Details of how to make one of these joints are at this blog post.

Since this joint type is the simplest and most cost effective, it is by far the most commonly used in light, medium, and many heavy duty applications.  For more heavy duty and not so simple applications, other solutions are available.

The standard connection joint type is not limited to use with square profiles either.  It can be used to join rectangular profiles to square profiles as well as rectangular profiles to rectangular profiles.

Probably the only drawback of this simple joint is that it is not readily re-located along the second profile piece should the need arise.  Another hole needs to be drilled to suit the hex key at the desired new location.  Admittedly, this situation doesn’t often crop up, but it does occasionally.  For details of one of many alternative solutions, see this blog post; what are clamping plates.

Full Body Joint

One variation of the standard connection is known as a full body joint.  A full body joint can be used where slightly heavier duty demands.  The main difference in this joint variation is that the drilled perpendicular hole is to suit the fixing screw rather than the hex key.  This adds a small amount of complexity, and hence time, to preparing the joint, but it remains a very cost effective joint.

T-Slot extruded aluminium profile joints - Standard connection - aluminium extrusion                            T-Slot extruded aluminium profile joints - Standard connection - aluminium extrusion

Diagrams from the Alusic catalogue showing two forms of a full body joint.

Joining the other size aluminium profiles

This basic type of T slot connection is not only cost effective it is also incredibly versatile. All of our profiles can be connected this way without the use of any accessories and different size profiles can be joined in this way.