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Using aluminium composite panels in T slot builds.

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.

Aluminium composite panel sighn in a T Slot Aluminium extrusion 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

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 helps to minimise 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

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 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

The Alusic aluminium extrusions come in nominal 6m lengths.  In reality, they are 6040 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.   

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.

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.

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 to cut your profile.

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 advise

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


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

30 Series Extruded Aluminium T-slot Profile

30 Series Extruded Aluminium T-slot Profile - aluminium extrusion

 

The Profilium 30 Series range of Extruded Aluminium T Slot profile consists of 18 different profiles in both 6 mm  and 8 mm slot sizes

We carry a large range of accessories to match these extrusions

 Visit our On line store and check out our extensive range of products

 

Aluminium T Slot extrusion

13 x 30 Extruded Aluminium T slot Profile

30 Series Extruded Aluminium T-slot Profile - aluminium extrusion

 

 

 

These profiles are extremely versatile can be used for a number of different projects. Our case studies have shown using T slot profiles to manufacture can dramatically reduces costs due to rapid assembly times and  and the fact that there is nor finishing such as painting required afterwards .In addition there is no hot work such as welding required and there is also no distortion due to weld contraction.

 

 

30 Series Extruded Aluminium T-slot Profile - aluminium extrusion

Aluminium T Slot Extrusion

60 x 60 Extruded Aluminium T Slot Profile

 

Because the assembly process required to build framework with these Profiles is so simple, it is easy to relocate components if required.It is also a easy to prepare a cut list and transport a large assemble as a flat pack to its final destination for assembly. this can result in a large saving in transportation costs and also allow for large structures to be assembled inside areas with limited access.

 

 

 

 

for resources on how to use our extrusions effectively go to this link How to do a Standard T slot connection

Contact

 

 

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

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

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

This is the standard joint type for the Alusic extruded aluminium profile range of products. It is the most cost effective and commonly used joint type.

The typical cost of this joint is around $0.34 using an M8x20 bolt (084.301.003) and 13×13 washer (084.303.001). And it can normally be assembled in under a minute. A leading competitor’s equivalent connection costs around $3.35 each and can take 3 times longer to achieve.

In some applications, an anti twist device can be used to replace 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 on the rare occasions it is needed.

Save time & money

The total time taken to complete a Competitor’s standard connection is 2-3 minutes. This, of course, depends on available tooling. Without appropriate tooling being available, it could take even longer. So, if we add this (up to 300% greater) labour cost to the higher material cost of the competitor’s connection, the choice becomes simple.

Also, with the Competitor’s connection, the dimension from the profile end to the centre of the cross bush is critical to the connection effectiveness.  If the correct dimension is not achieved with sufficient accuracy, the length of profile effectively becomes scrap.  Whereas, with the Alusic connection system if the pilot hole location is not correct then it’s simply a matter of drilling another hole at the correct location. In some cases, the adjoining profile may need to be tapped accordingly, but those cases are quite rare.

No milling or special tooling

The dimension for the pilot hole with Alusic profile is predetermined by the drilling jig (084.818.001) 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. This can ensure that the screw has the tightest possible fit to eliminate any possibility of vibration affecting the joint.  The potential for a loose joint can also be eliminated with the use of thread locking products such as Loctite. It must be said, though, that the need for either of these is extremely rare because the joint is highly effective in the first place.

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 at the top of this page.  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.

With 350 individual connection points in the structure, a saving of between 300% and 500% in labour costs using Alusic standard connectors is possible.  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. Then there is the cost of the connector parts themselves at around $1,170.

Using the Alusic standard bolt connection, taking less than a minute each, all the connections could be completed in 5.8 hours. The connector parts would only cost around $120. That is three times faster than the Competitor’s system representing an enormous saving in labour costs alone. This represents a saving of around 11.7 hours, on that structure, and about $1050 in parts.