Custom made Workbenches and Workstations.

When it comes to providing a work station or workbench it is important to get it right

T Slot Aluminium Work stations GAP Engineering

Poorly planed or implemented work stations can have significant impacts on

  • work place health and safety
  • quality control
  • productivity
  •  profit margins

Custom made Workbenches and Workstations. - aluminium extrusion

What to look for in a well designed workstation

1. Correct Work Height
− An operator’s arms should be below shoulder level
− Precise tasks: 50mm below elbow
− Light assembly: 50 -100mm below elbow
− Heavy work: 100 – 200mm below elbow

2. Properly Adjust Work Equipment to the Task
− Adjust the workstation:
− Seat height and angle; footrest height and angle
− Adjust the work piece and parts containers:
− Work piece and parts containers in optimal positions (refer to points 3 and 4)

3. Work Piece & Parts Container Layout
− Optimise container layout to reduce wasted motion and speed up throughput
− Heavy and/or most used parts should be placed in the closest containers
− Optimal container layout is within a 400 mm radius, as measured from each shoulder

4. Working Area
− Maximum grab area: 540 mm radius, measured 160 mm to the left and right from the
centre line and front edge of the work top
− Optimum grab area: 280 mm radius, measured 160 mm to the left and right from the
centre line and front edge of the work top

5. Consider Fields of Vision
− Operators should view the work piece without turning head or eyes
− A 15° view angle requires no head or eye movement to grab parts
− A 35° view angle requires only eye movement to grab parts
− Viewing distance to a Monitor should be between 350 mm and 750 mm

6. Match Light Intensity to the Work Task
− Standard assembly tasks: 500—750 lux
− Complex tasks (e.g. electrical assembly): 1000—1500 lux
− Delicate and/or critical work: 1500—2000 lux

7. Do Not Work Above the Heart
− Keep all work below the heart to enhance blood circulation
− Reduce static holding during assembly as it increases muscle fatigue

8. Load bearing capacity

9. Durability of the work surface                                                                                                                                                                                                             

Custom made Workbenches and Workstations. - aluminium extrusion

For more detailed information please download our Work Stations and Benches Brochure

In order to make the most of available space and resources it is also important to consider if it would be beneficial to integrate one or more of the following into your Workstation 

  • Power and Data
  • Lifting units
  • Mobile parts shelves and trolleys
  • Drawers and storage compartments
  • parcel chutes
  • lighting
  • linear rails and guides
  • adjustable foot rest
  • monitor arms
  • compressed air outlets
  • Shelving systems
  • tote bins
  • integrated machinery such as co-bots or conveyors
  • safety guarding

If you would like would like us to help you get the best solution for your workstation requirements please complete this form and we will get back to you 


Please contact me


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-physical systems

The first three industrial revolutions transformed and revolutionised our society  and with each stage our world has 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 scanned with a 3D scanner in order for a complete CAD model of the entire workplace to be created. every detail such as flow of work ,positioning of safety fencing ,height restrictions and positioning of equipment can be thoroughly analysed before any other steps are taken.

All of out accessories are available for download in several CAD formats and 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


The more things change the more they stay the same and as long as there is a requirement to convert ideas into physical functioning machines there will always be a requirement 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 modified .Furthermore the components can be recycled for other prototypes without any cutting or welding of metal.We carry over 60 varieties of T Slot profile in stock as well as a large range of 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.


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 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

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 system 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.