Understanding Aluminium Fabrication, Its Process and Importance.
Release Time:
09 Jan,2025
In a process called electrolysis, using negative and positive cathodes made of carbon, the alumina is then converted to a liquid state with the creation of CO2. This liquid aluminum is then poured into different forms that produce sheet ingots or slabs, which are then used to create aluminum plates and sheets.

Many products and items on this site rely on aluminum plates. But have you ever wondered how aluminum plates are made or where they come from?
The process begins with mining bauxite, the raw material for aluminum. Bauxite, a clay-like soil rich in aluminum, is typically found a few meters below the surface, most abundantly near the equator.
After mining, the bauxite is washed to remove any clay, then ground and prepared for extracting aluminum oxide, or alumina. This involves mixing the crushed bauxite with hot caustic soda and lime. The process purifies the resulting crystals, producing alumina, the essential component for creating aluminum metal.
The next step in this process is the creation of the aluminum metal. This is done with the help of carbon and electricity. In a process called electrolysis, using negative and positive cathodes made of carbon, the alumina is then converted to a liquid state with the creation of CO2. This liquid aluminum is then poured into different forms that produce sheet ingots or slabs, which are then used to create aluminum plates and sheets.
Aluminium sheet fabrication involves creating structures through cutting, bending, and other assembly processes. Each aluminium type or alloy demands specific machining techniques, and Great Lion specializes in delivering top-tier fabrication services tailored to your requirements.
The range of fabrication methods is extensive, reflecting the versatility of aluminium in various applications. These methods include extrusion, drawing, machining, forming, welding, cutting, drilling, milling, and routing. Aluminium is highly suitable for diverse fabrication needs due to its durability, lightweight nature, corrosion resistance, exceptional ductility, and suitability for customized shaping.
Popular Aluminium Fabrication Processes
Aluminium fabrication involves using specialized tools to join aluminium pieces, a task best handled by experts who understand health and safety regulations.
This process, distinct from aluminium extrusion, begins with preparation:
Material Preparation: Ensuring Quality
The aluminium surface is inspected and treated with specialist methods to ensure quality. Proper surface preparation is crucial, particularly for processes like welding, where coatings such as welding primers protect the metal during fabrication.
After preparation, common aluminium fabrication processes include:
CNC
CNC systems automate machine tools for precise finishes. They enable automated cutting and movement of aluminium fabrications, increasing output volume when required.
Cutting
Aluminium sheets or bars are cut into specific shapes and sizes using tools like saws, shears, lasers, or waterjets. CNC machines provide exact, bespoke cuts with tight tolerances, operated by expert fabricators.
Pressings
When sections can’t be extruded, pressings are used to fold and form aluminium sheets into unique shapes with machines like press brakes or rollers.
Drilling and Slotting
These techniques create precise holes and entry points for applications in aerospace, construction, automotive industries, and more. They also allow parts to fit together seamlessly for large-scale projects.
Welding
Aluminium is welded using metal inert gas (MIG) or tungsten inert gas (TIG) tools to cut, combine, or bend metal. This joins multiple pieces to create larger products, similar to drilling and slotting.
Countersinking and Tapping
Using advanced CNC technology, countersinking creates holes for screws or bolts, while tapping cuts threads inside holes for smooth screw or bolt insertion. Both methods ensure precision and efficiency.
What Happens After the Fabrication Process?
The final step in aluminium fabrication is quality control. Each method has potential for errors, so every part undergoes thorough inspection.
After fabrication, additional finishes can enhance strength, durability, corrosion resistance, and visual appeal. Common finishes include:
- Aluminium polishing
- Aluminium powder coating
- Aluminium anodising
Choose Great Lion for Aluminium Fabrication
Great Lion has the expertise to turn your ideas and designs into reality. Aluminium fabrication is complex, but our skilled team ensures reliable, professional, and safe solutions tailored to your needs.
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