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Aluminum Fabrication

Large-Scale Aluminum Fabrication & Machining

Aluminum offers an exceptional strength-to-weight ratio, excellent corrosion resistance, and high thermal and electrical conductivity. However, fabricating large aluminum structures requires specialized expertise, dedicated equipment, and strict environmental controls to prevent cross-contamination and weld porosity.

At Openex, we provide comprehensive, massive-scale aluminum contract manufacturing. From heavy aluminum plate rolling and high-speed CNC routing to complex TIG/MIG structural welding, we serve industries where lightweight durability is critical, such as aerospace, marine, transportation, and industrial automation.

Our Aluminum Capabilities

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    High-Speed CNC Machining Optimized spindle speeds and chip evacuation for large aluminum enclosures and plates.
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    Precision Laser Cutting Fiber lasers specifically calibrated to cut highly reflective aluminum alloys cleanly.
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    AWS Certified Welding Specialized AC TIG and Pulsed MIG welding to ensure deep penetration and zero porosity.
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    Plate Rolling & Press Braking Cold forming massive aluminum sheets without cracking or surface marring.

Aluminum Grades We Work With

Different applications require different mechanical properties. We inventory and process a wide variety of aluminum series to meet your exact blueprint requirements.

Alloy Grade Key Characteristics Common Applications
5052 Aluminum Excellent corrosion resistance (especially saltwater), highly formable, easily weldable. Marine components, fuel tanks, electronic enclosures.
6061 / 6061-T6 The industry standard. Outstanding strength, machinability, and weldability. Structural framing, base plates, transportation chassis, aerospace parts.
7075 Aluminum One of the highest strength aluminum alloys available; comparable to many steels. High-stress aerospace components, military equipment, highly stressed structural parts.
3003 Aluminum Moderate strength, highly workable, excellent resistance to chemical attack. Chemical equipment, ductwork, heat exchangers.

Dedicated Clean Processing

To prevent galvanic corrosion and inclusions, Openex maintains strict material separation protocols. We utilize dedicated grinding tools, stainless steel wire brushes, and isolated welding bays exclusively for our aluminum projects to ensure your finished product is pristine and defect-free.

Frequently Asked Questions

What aluminum alloys can you fabricate? ▾
We commonly fabricate a wide range of aluminum alloys, with a specialization in 5052 (for marine-grade corrosion resistance), 6061-T6 (the structural workhorse), and 7075 (for high-stress aerospace applications). We can source and process virtually any commercial grade based on project requirements.
What are the challenges of welding large aluminum structures? ▾
Welding aluminum presents several challenges. Its high thermal conductivity requires higher heat input, which can lead to distortion in large structures. It also has a tendency to form a porous oxide layer, which must be meticulously cleaned before welding to prevent defects. We use specialized AC TIG and pulsed MIG welding processes, along with dedicated cleaning procedures, to create strong, non-porous welds.
How do you prevent cross-contamination when working with both aluminum and steel? ▾
Preventing galvanic corrosion from steel contamination is critical. Openex maintains dedicated, isolated bays for aluminum fabrication. We use separate sets of tools, including grinders, wire brushes, and handling equipment, that never come into contact with ferrous metals. This strict separation ensures the purity and longevity of our aluminum fabrications.