Posts

Aluminium T-Slot Extrusions for the Film Industry.

Alusic T-Slot Aluminium extrusions can be used to make a diverse range of equipment for the film industry.  From prop and camera support equipment to sound and electrical gear.  You will be hard pressed finding a more versatile and practical solution for your needs.

    

Here at GAP Engineering, we can design and manufacture the equipment you need to keep your project running smoothly.

We supply Alusic t-slot aluminium extrusions in a range of sizes.  Also, we supply all the joining hardware and other accessories that may be needed for your project.  As a result, these parts can be used to manufacture a huge variety of different equipment.

Aluminium extrusions are suitable for:

  • Trolleys and carts for electrical, sound, lighting and other crew 
  • Robotics
  • Linear systems
  • Lighting displays
  • Movie sets and props 
  • Camera mounting equipment
  • Display units
  • Screens such as green screens and photography booths
  • Point of sale structures
  • Machine frames
  • Safety guards and fencing
  • Industrial workstations
  • Workbenches 
  • Clean rooms 
  • Conveyors 
  • Cabinets 

Regardless of what you need to build, t-slot extruded aluminium profiles and accessories can help you save time and money on your project.

How can we help you?

Consulting and Design

Using our 3D CAD modelling software, we can analyse your design and check it against your requirements.  This can be done before cutting any material and before fabrication begins.  This results in minimising the potential for material waste and other unnecessary costs.

Do you do your own design work?  If so, we have CAD files for most Alusic profiles and accessories.  Having these on hand can make your design work so much easier and quicker.  We can make them available on your request.  We would only ask that you sign up to the Alusic confidentiality agreement.

T Slot Aluminium Profile

If you can’t find what you are looking for here, then you are welcome to contact us for further information.  We even have a full catalogue of the Alusic range of t-slot aluminium profiles and accessories.  We can make that available as a PDF file.  

You can find a wealth of resources here to help you get started.

If you don’t have time, or facilities, to do your own design work then we can design the project for you.  Just tell us all your requirements then we can design a solution.

Aluminium Extrusions and Accessories 

Because we stock an extensive range of t-slot aluminium profiles and accessories, we are able to solve a multitude of challenges with minimal delay.  Having more than 60 different profiles ranging from 20mm to 140mm, the range of options is huge.

The range of accessories we carry covers everything from

  • T-Nuts and Bolts (designed for profile).
  • Clamping Angles and Connectors.
  • Caps and Cover Strip.
  • Feet, Anchor Brackets, and Castor Wheels.
  • Hinges and Panel Brackets.
  • Door Locks, Catches, and Counter Balances.
  • Conveyor Components.
  • Linear Guide Components.

You can see our full range at our Online store  or you can download a copy of our catalogue

 

Manufacturing 

You can focus on your core business while we take care of your project.  With experienced staff and a well equipped manufacturing facility we have the capacity to manufacture just about anything.  This includes custom parts as may be required for your project.

We design and manufacture unique equipment perfectly suited to your individual requirements.

Visit our web-store.

T-Slot Aluminium extrusions and components for your next project

Are you looking for a better way to build just about anything you can think of?

Before starting to build your next project take a close look at the Alusic t-slot extruded aluminium profile system.  We are sure you will be impressed with just how user friendly and adaptable this system really is.


Alusic T Slot Aluminium profile extrusion frame

When creating something new, you usually need to start with some sort of framework.  The more versatile the material you choose to build that framework, the easier it will be make any needed changes as the creative process flows.  T-Slot Aluminium extrusions and accessories are an exceptional example of an versatile material for building frames.  Frames that are strong, light weight, and easily adapted to different design needs.  The same applies for a multitude different uses and applications.

Imagine what you could build with this system.

We supply a large range of T-Slot Aluminium Profiles and accessories and all the material you need for your project.  We can cut and prepare the material for you so that you can assemble it on site.  Or, we can manufacture the entire project and assemble and commission on site for you.    

T-Slot Extruded Aluminium Profile

Regardless of what you are trying to build, Alusic t-slot aluminium extruded profiles and accessories will save you time and money.


We can help you each step of the way.

Resources 

From CAD models to how to videos, and catalogues to informative blogs. We can provide all the information and resources that you might need to help you make informed decisions about using t-slot aluminium profile for your next project.  Contact us for more information.  

Consulting and design

We can help you to learn everything you need to know about using t-slot aluminium extrusions and accessories. So you can start your next project with the confidence you need to use t-slot extrusions.  Upon request, we can supply all the CAD models you need to easily design your own project.

Alternatively, you can get us to design the project for you. We have 3D CAD and experienced operators on hand to make the design process as easy as possible. Also, we have a highly skilled and experienced team of people who can build your project for you. Our people can also install your project on your site, if you need.

T Slot Aluminium Profile

Parts and Accessories 

We stock an extensive range of accessories including caps and covers, connectors, linear actuators and guides, supports, and hinges to help you create solutions to a great variety of challenges. 

Our range of aluminium profile ranges from 20 to 140 mm wide. We have over 60 different profiles available so there is something suitable for almost any use you can imagine.

You can see our full range at our Online store or you can download a copy of our catalogue.

Accessories for extruded T slot Aluminium Profile
084 301 002 Alusic screw M8 x 16
Clamping angle connectors
Articulated joint Alusic T Slot Aluminium Profile

Manufacturing 

We can turn your imagination into reality and manufacture  what you need for you so that you can get on with your core business while we take care of your project.

T Slot profile machine
Custom made workbench
Aluminium profile workstations T Slot

T-Slot Extruded Aluminium Profile is suitable for:

  • Display units
  • Point of sale structures
  • Machine frames
  • Safety guards and fencing
  • Industrial work stations
  • Workbenches 
  • Clean rooms  
  • Cabinets 
  • Trolleys
  • Robotics
  • Linear systems
  • Conveyors 
  • Lighting displays
  • Movie sets and props 
  • Camera mounting equipment

Do you know what Aluminium T-Slot extruded profiles and accessories can be used for ?

Actually that question is probably a bit harder to answer than it would initially appear.

We are fortunate to work in an industry where we are exposed to a lot of highly creative and intelligent people.  As a result we constantly encounter people who are using our products in new and interesting ways.

Do you know what Aluminium T-Slot extruded profiles and accessories can be used for ? - aluminium extrusionNo matter how complex or unusual your project, chances are that t-slot extruded aluminium profile will be able to play a role in helping you achieve a cost effective and practical solution.  This applies to a large range of projects.  From material handling to automation, packaging to prototyping, and everything in between.  It’s very common to see t-slot aluminium profiles being used in the modern industrial environment as well as in other areas.

The main motivation for using T-Slot is that it greatly reduces the amount of time required to build.  This is because you don’t need to prepare and weld joins.  You also don’t need to prepare and paint a whole structure once you have built it.  Both welding and painting are messy, expensive and time consuming.  If you need to weld or paint in a sensitive environment the noise, fumes, heat, or just plain dirt generated can become a considerable problem.

T Slot Aluminium Extrusions and accessories

GAP Engineering T Slot Aluminium Extrusions and accessories

This list is a summary of the types of applications where we often choose to use T-Slot Extruded Aluminium Profiles over other methods of construction.

  • Camera mounting equipment
  • Audiovisual display equipment
  • Conveyors and elevators
  • Industrial workbenches
  • Clean rooms
  • Trade-show displays
  • High altitude training rooms
  • Display units
  • Machinery and equipment frames
  • Safety fencing
  • Lifting units
  • Trolleys, racks, and cabinets
  • Laboratory jigs and machine frames
  • CNC router beds and frames
  • Architectural features
  • Vehicle fit outs
  • Light boxes

Do you know what Aluminium T-Slot extruded profiles and accessories can be used for ? - aluminium extrusion        Do you know what Aluminium T-Slot extruded profiles and accessories can be used for ? - aluminium extrusion

Do you know what Aluminium T-Slot extruded profiles and accessories can be used for ? - aluminium extrusion        Do you know what Aluminium T-Slot extruded profiles and accessories can be used for ? - aluminium extrusion

Do you know what Aluminium T-Slot extruded profiles and accessories can be used for ? - aluminium extrusion        Do you know what Aluminium T-Slot extruded profiles and accessories can be used for ? - aluminium extrusion

Accessories for extruded T slot Aluminium Profile      4040 T slot clamping plates extrusion accessories

For more information about this product please go to this web site Profilium resources.

We have a team of engineers ready to design your solution using Alusic Aluminium Profiles and accessories.

Please contact us if you require more information

Do you know what Aluminium T-Slot extruded profiles and accessories can be used for ? - aluminium extrusion

Engineers working on development of automated production line with robotic parts and applied software in order to increase productivity. Precise engineering on electric parts of automated production line.

GAP Logo with Web Address

Contact

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 material.  Material that some how wasn’t quiet long enough to be useful.  Nevertheless it ended up being a lot of material.

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

The Alusic aluminium extrusions come in nominal 6m lengths.  In reality they are usually between 6.020mm and 6.050mm in length.  Some of that extra length is needed because they come as finished from the extruding machine, not accurately cut square with a saw.   It is also useful since a certain amount is lost with every cut due to the blade kerf.   

Optimise your cutting list

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.

If your cutting list is relatively simple, then our freely downloadable cutting list template might be your best option.  Don’t forget to allow for saw blade kerf in your cutting list.  For example, the blade in our saw has a kerf of 3.7mm, so we allow 4mm in our cutting lists.

Cutting and delivery

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.

T-Slot profile saw
T-Slot aluminium profile saw

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



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

Contact

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.

Information about different styles of pawl clamp can be found on pages 2.53 to 2.56 of the Alusic catalogue.

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. Exact dimensions for the holes to suit each pawl clamp are shown in the Alusic catalogue. The number of holes is determined by the number of pawl clamps the joint needs (2 in this example).

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 (084.101.003), a 1 slot 40×40 (084.102.006), and a 6 slot 45×90 (084.101.019).

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 – Cube joint

Cube Joint

In this post we focus on the cube joint or the 3-way body connection. 

In the example below we use a joint for round profile (084.310.001). This is just one of the range of different styles of cube joint that can be found in the Alusic catalogue. Pages 2.80 to 2.86 show different joint styles along with some of the many polyamide caps available to provide a neat smooth finish to joints.

Joint for round profile

cube joint

Joint for round profile ready for assembly

Here we are joining three pieces of 32×32 round profile, 084.101.010. Each piece is prepared by cutting the end square and tapping the profile core hole M8

 

Assembling the joint

To start assembling the joint, the studs are screwed into those tapped holes in the ends of the pieces to be joined.

cube joint

Screw the studs into the tapped holes

 

Now slide the cube joint block onto the stud in the first piece of profile to be joined.  Then do up the associated grub screw so that the block is held in place on the stud. The grub screw will engage with the groove around the stud to securely hold the profile piece to the block.

cube joint

Attach the first piece of profile to be joined

 

Continue the assembly by sliding the the block onto the stud in the second piece of profile in the same manner as for the first.

cube joint

Attaching the second piece

 

Attaching the last piece is the same as the first and second except that the hex key to do up the grub screw needs to be long enough to fit in the profile slot to get to the grub screw.

cube joint

Attaching the last piece

 

Finally, make sure the ends of the profile pieces are nicely aligned with the cube joint block and tighten the grub screws to complete the joint.

 

In conclusion

So there you have it, a 3-way body connection (cube joint) using a joint for round profile.

 

 

 

 

 

 

 

T-Slot extruded aluminium profile joints – angular joint

Profile Joints – Part 4

Angular joint

In this post we focus on the angular joint; what it is and how to put one together.  This is the fourth in our series of posts on aluminium profile joints.

angular joint

Angular joint – 45°

 

Essentially, the angular joint is a variation of the linear joint. See our earlier blog post on linear joints.  While the linear joint could be said to have an angle of 0°, angular joints are available in 30°, 45°, 60°, and 90° fixed versions.  The Alusic catalogue has technical details of those angular joints on pages 2.48 through to 2.64 inclusive.

If those fixed angles aren’t enough for you, Alusic also has variable angle joint solutions in the catalogue. They can be found on pages 2.71 and 2.72.

variable angle joint

Central swivel joint – variable angle

 

Cutting the extrusion

One of the obvious issues with joints that are not linear or square, is that without both profile pieces mitre cut to the correct angle, the joint will look a bit ugly.

angular joint

Angular joint without mitre cuts

Fortunately these days, reasonable quality mitre saws are relatively inexpensive and easy to get. The only trick is getting a good quality blade and cutting lubricant.

To get a good tight joint you need really good clean cuts. A hacksaw just isn’t going to be good enough, no matter how good your skills. Even a powered hacksaw or band saw isn’t going to give you a great finish.

We use a 400mm diameter tungsten carbide tipped blade in a drop saw designed for cutting aluminium.  It can be used to cut extrusions off at almost any angle and produces very nice clean cuts.  We offer a modestly priced cutting service for any customer needing their extrusions cut to length.

Preparing a joint

As mentioned above, the key to getting a good tight joint is cutting the extrusion cleanly and at the correct angle. The correct angle usually being half the nominal angle of the joint. In this example, the nominal angle of the joint is 45° so we have mitre cut the pieces to be joined at 22.5°.  This joint type usually requires two angular joints to ensure sufficient joint strength and balanced load carrying ability.

angular joint

Angular joint ready for assembly

 

 

 

 

 

 

 

 

 

 

Putting it together

As you can see in the first diagram above, the angular joints fit neatly inside the t-slot in the extrusion. One of the advantages of this joint type is that there are no parts extending beyond the perimeter of the profile.

The first step is to slide the angular joints into the t-slots of one of the profile pieces and screw down the grub screws to take up all the play in the slot. Do not properly tighten the grub screws just yet.  Simply nipping up only one of the grub screws at this stage is enough.

angular joint

Angular joint partly assembled

The joint is completed by pushing the ends of the profile pieces firmly together then tightening the grub screws so that the grub screw flat ends bear down on the bottom of the t-slot.  This effectively clamps the angular joint into the t-slot of the extruded profile.  Before properly tightening the grub screws make sure the ends of the profile pieces are nicely aligned.

angular joint

Angular joint completed

 

 

 

 

 

 

 

 

Once the grub screws are properly tightened, you should have a rather tidy nice rigid joint.

 

 

 

If you want a copy of the Alusic catalogue to view on your 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 – Stronger connection

Profile Joints – Part 2

As a person who is regularly building all manner of things using T slot aluminium extrusions, I occasionally come across a situation where a simple joint using a fixing screw just isn’t going to cut it.  Today I am going to introduce you to just a few of the many different methods of joining T slot aluminium profiles using items found in the Fixing Accessories section of the Alusic catalogue.

Late last year I was putting together a batch of custom designed workbenches when the owner announced that they wanted an LED light panel mounted about 1200mm above the main work surface of each workbench.  No problem, I thought.  Just add a pair of upright sections at the back of each workbench, build a frame to hold each panel and attach to the uprights.

That was all fine until it was let slip that some of the workbenches were to be indirectly attached to pieces of equipment that would put some not insignificant vibrations into the workbenches a number of times per day.  I quickly realised that the simple jointed cantilever design I’d thought of would likely not cope with the dynamic loads generated by oscillations, caused by vibrating machinery, of the panel and frame on the uprights.  Even though that simple jointed cantilever design would be fine with the panel as a static load.

So, a quick design review later.  It was decided to use fixing angles (084.305.033) for the main joints and make braces for the uprights using some joint angles (084.305.011).

fixing angle 43 x 86  joint angle for 40 x 40 profile

 

The fixing angles made the joints very much stronger than they would have been otherwise.  Using joint angles to make braces for the uprights stiffened the structure enough to almost eliminate oscillations that would be generated by the vibrating machinery.  Thinking about it now, just the braces may have been adequate to keep oscillations, and hence joint loads, down enough for the original simple joint design to cope.  Oh well … I think there is a saying in the engineering world that has something to do with “belts and braces”.

A few months after that, the same owner said they wanted some more workbenches (different design of course) also with the LED light panels.  This time though, they wanted to be able to adjust the braces up or down a little for operator head clearance.

At first that seemed a bit complex, not to mention costly.  A stock of different length braces to be removed and replaced by maintenance people as and when required.  I could see there would be no way to guarantee that adequate length braces would not all soon be replaced by the shortest braces, or even removed completely.  Not a viable option in my view.

Then the Alusic catalogue came to the rescue.  Instead of using a joint angle at the end of each brace and making different size braces it was decided to use a screw swivel joint (084.311.010) at the end of each brace.  That would ensure every LED panel support would be adequately braced as well as have a small amount of adjustment using just a hex key.

brace using screw swivel joints

To get your own PDF of the Alusic catalogue, fill in your name and email address on our site main page https://gapengineering.com.au/ and we will send an email with the download link.

 

 

 

 

 

 

 

 

 

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.

Determining the deflection of a profile under load

084.102.001-c

Using the information supplied in the catalogue you can calculate the amount of deflection you can expect to get when applying a specific load to a specified span of profile.

 

Engineering Calculations Load - Deflection Chart

 

 

Using this diagram we can work out how much a given profile is expected to deflect under a given load condition. The example shown here is for an 800mm long section of profile with a moment of inertia of 10cm^4 and an applied load of 3000N.

Please note that the moment of inertia, Ix & Iy, of each profile is included in the Alusic catalogue along with other information such as section modulus and mass per metre.

Starting along the bottom of the chart, find the length of the profile, in this example the blue vertical line at 800mm. On the left side of the chart find the applied force, in this example the blue horizontal line at 3000N.

Now, from the intersection of the horizontal and vertical lines, draw an oblique parallel line. Then, on the right side of the chart find the moment of inertia of the profile, in this example the blue horizontal line at 10cm^4. Where this horizontal line intersects with the drawn oblique line, draw a vertical line up through the deflection bars above the chart.

The expected maximum deflection of the length of profile can now be read directly from the deflection bar for each of the three figured load cases; cantilever, pinned supports, fixed supports. In this example the expected deflection would be 73mm, 4.7mm, or 1.4mm respectively.

The Load-Deflection diagram we are using here can be found in the Alusic catalogue. The catalogue is available as a FREE download from our web site. https://www.gapengineering.com.au/ Please be aware that this is an 88MB, 796 page PDF file

Obligatory caveat.

This example provides only a general indication. The exact dimensions of, and loads on, each structure must be calculated by the customer separately from this example.

Technical Specifications of T-Slot Aluminium Profile

Extruded Aluminium T slot profiles

Our extruded T slot Aluminium profiles generally come in one of the 3 standard slots as shown below. Please contact us if you need more information

6mm Slot – 30 & 60 Series

Detail of 6mm slot in 30 series extrusions

8mm Slot – 40 & 80 Series

Detail of 8mm slot in 40 series extrusions

8mm Slot – 45 & 90 Series

Detail of 8mm slot in 45 series extrusions

Technical Data for Alusic Aluminium Profile

All extruded aluminium profiles are manufactured by Alusic SRL (Italy) using a primary aluminium alloy EN-AW 6060 (Al Mg Si  0.5).  The metallurgical state of the extruded aluminium bars is T5/T6 (solution heat treatment, tempered and artificially aged) to ensure long lasting dimensional and mechanical property stability.

The dimensional tolerances for aluminium profile extrusion are in compliance with the European standard UNI-EN 12020-2 for precision extrusions.

Chemical composition of alloys:

 Alloy  Cu  Fe  Mn  Mg  Si  Zn  Cr  Ti  Al
 6060  0.10  0.1–0.3  0.10  0.35–0.6  0.3–0.6  0.15  0.05  0.10  Rest
 6063  0.10  0.35  0.10  0.45–0.9  0.2–0.6  0.10  0.10  0.10  Rest

The mechanical properties after heat treatment:

 Alloy Maximum Stress
(N / mm2)
Yield Stress
(N / mm2)
Extension
(A%)
Hardness
(HB)
 6060 190 150  8 70
 6063 215  170  8 75

Characteristics for the design of aluminium structures:

Elastic (Young’s) modulus 69000 N/ mm2
Electrical resistivity 0.033 Ω mm2/ m
Thermal conductivity 210 W/ mK
Melting temperature 615 – 655 oC
Thermal expansion coefficient 25 x 10-6 K-1

In addition to a guarantee of high quality and dependability of aluminium products, ALUSIC is also certified to comply with the international standard for quality assurance ISO 9001:2000.

Further information, including R&D advice can be obtained in collaboration with Profilium and Alusic’s technical and commercial departments.  Please contact us for more information.

Need more information?

If you want more information on how to use our profiles, the benefits of using the Alusic profile system or you simply want a brochure or catalogue, then go to the aluminiumprofile.com.au downloads page.

Alusic aluminium profile and accessories – faster, more cost effective assembly

STANDARD BOLT CONNECTION

A simple, yet strong joint can be achieved by using both
a socket head screw, with a square washer, screwed into theCONNECTION.JPG core hole of the profile (see image on right).  A small pilot hole is drilled opposite where the joining profile is to be located.  This is the access for a hex key to tighten the screw. 

This is the standard joint for the Alusic range and is a very cost effective outcome.  ⇒ The cost per Alusic connection as shown is $0.34 using an M8x20 bolt (084.301.003) and 13×13 washer (084.303.001).
⇒ Achieves an extremely simple, yet strong connection in under a minute.

A leading competitor’s equivalent connection costs $3.35 each and takes about 3 times longer to achieve.  In some applications you may also add our anti twist device that replaces the square washer in the standard connection.  The twin tabs on the anti twist device go into the slots of the connecting profile to prevent the joint twisting – a simple and effective solution.

SAVE TIME & MONEY

The total time taken to complete a standard Competitor’s connection is 2-3 minutes depending on available tooling; with the cost of the competitor’s connection being up to 300% greater in labour costs alone, let alone the higher material cost of the connectors. 

With a competitors connection, the distance from the profile end to the centre of the cross bush, is critical to ensure the connector works effectively.  If this is not achieved accurately this length of profile is left unusable.  Whereas, with the Alusic connection system the pilot hole is simply re-drilled and the adjoining profile tapped accordingly.

NO MILLING OR SPECIAL TOOLING

The distance of the pilot hole with Alusic profile is predetermined by the drilling jig with several millimetres of adjustment from side to side.  With the Alusic connecting system there is also the option of self tapping the screw into the adjoining profile as opposed to pre-tapping to ensure the connector has the best possible fit and to eliminate any possibility of vibration affecting the joint.  The potential for a loose join can also be eliminated with the use of thread locking products like LocTite although this very rarely needed as the connection is extremely effective without this process.

COST BENEFIT

To demonstrate some of the labour savings that can be achieved using the Alusic system a cost comparison exercise was undertaken on the structure shown above.  The resulting time and motion study estimated the labour saving that could be achieved using the Alusic aluminium system when compared with another high quality European competitor’s profile.

There are 350 individual connection points on this frame with a saving of between 300% to 500% in labour costs using Alusic standard connectors.  In other words, if using a competitor’s connector that takes up to 3 minutes per connection point, you would require 1,050 minutes or 17.5 hours just to complete the connections on this structure and cost it would cost $1,172.50* for the connectors. 

Using the Alusic connector it takes less than 1 minute per connection point, and you would complete the connections in 5.8 hours and it would only cost $119.00* for the connectors! That is 3 times faster than the competitor and an enormous cost saving in labour costs alone. That is a saving of 11.7 hours per structure and $1053.50* in parts!!