How to manufacture modern aluminium windows and doors?

1. Design & Engineering

• Custom Specifications: Begin by analyzing client requirements (dimensions, style, thermal performance, security needs) and architectural standards (e.g., wind load, water tightness).
• CAD Modeling: Use computer-aided design (CAD) software to create detailed 3D models, optimizing frame profiles, glass integration, and hardware placement.
• Structural Simulation: Conduct virtual stress tests to ensure durability against environmental factors (temperature changes, humidity, impact).

2. Material Selection

• Aluminium Alloys: Choose high-grade alloys (e.g., 6063-T5) for their strength-to-weight ratio, corrosion resistance, and malleability.
• Glass: Select specialized glass (double/triple glazing, low-emissivity (Low-E) glass, tempered or laminated safety glass) based on insulation, soundproofing, and safety requirements.
• Hardware: Source precision components (hinges, locks, handles, weatherstripping) for smooth operation and energy efficiency.

3. Aluminium Profile Extrusion

• Billet Heating: Heat aluminium billets to ~500°C for optimal malleability.
• Extrusion: Force heated billets through custom steel dies to form complex frame profiles (e.g., sashes, jambs) with consistent cross-sections.
• Cooling & Aging: Quench extruded profiles in water to lock in shape, then heat-treat (age hardening) to enhance strength.

4. Profile Processing

• Cutting: Use CNC saws to cut profiles to exact lengths with high precision (±0.1mm tolerance).
• Milling & Drilling: CNC machines create holes, slots, and notches for hardware installation and assembly.
• Surface Treatment:
  • Anodizing: Electrochemically coat profiles with a protective oxide layer (available in various finishes).
  • Powder Coating: Apply electrostatically charged powder paint, then cure at high temperatures for a durable, scratch-resistant finish.
  • Wood Grain Simulation: Use thermal transfer printing for aesthetic wood-like textures.

5. Assembly

• Frame Construction: Join profiles using corner connectors, screws, or structural adhesives, ensuring square angles and tight joints.
• Glass Installation: Apply high-performance sealants (silicone) and insert glass panes into pre-fabricated grooves, adding spacers for thermal insulation.
• Hardware Fitting: Install hinges, locks, handles, and weatherstripping to ensure smooth operation and air/water tightness.

6. Quality Control & Testing

• Dimensional Checks: Verify compliance with design specifications using precision measuring tools.
• Performance Testing: Conduct tests for:
  • Water tightness (resistance to rain penetration)
  • Air permeability (to prevent drafts)
  • Wind resistance (structural integrity under pressure)
  • Thermal insulation (U-value measurement)
  • Security (lock strength and impact resistance)

7. Packaging & Delivery

• Protective Packaging: Wrap finished products in film or cardboard to prevent scratches during transit.
• Logistics Planning: Arrange transportation with proper bracing to avoid warping or damage.