1102 Foundry St. Coatesville, PA 19320     Mon. - Fri. 8am-5pm
Contact Us     Call Us: (610) 384-7440

Aluminum Fabrication

Choose Affordable, Dependable, Custom Aluminum Fabrication 

When weight is a crucial factor in fabrication—and when corrosion resistance, conductivity, and cost are features that must be considered—custom aluminum fabrication may be an option. Whether your engineer has recommended aluminum fabrication, or you’d like to speak with a fabrication expert at Brandywine Valley Fabricators about the benefits of using this lightweight, malleable metal, we’ve got your budget and the best interest of your project in mind.

The Many Faces of Aluminum in Fabrication

Aluminum has long been chosen for its corrosion resistance, light weight, and low cost. Here are just a few of the places you can expect to find custom aluminum fabrication:

  • Airplanes
  • Automobiles
  • Watercraft
  • Bicycles
  • Roofing
  • Siding
  • Gutters & Downspouts
  • Window & Door Frames
  • Scaffolding
  • Ladders
  • Wheelchairs
  • Prosthetics
  • Camping Gear
  • Toolboxes

Of course, this is just a small sampling of what’s possible with custom aluminum fabrication. Artists’ creations, prototypes, and all kinds of industrial equipment can be manufactured with aluminum, and there’s no telling what our next aluminum project will be.

We’ve got plenty of projects for you to view in our photo gallery, and of course, we are here to answer all your questions or chat about your next project. Contact us today!

The Aluminum Fabricator You Choose is Important

Aluminum has many advantages; however, aluminum fabricators can encounter many challenges (that can result in imperfections or complete failure) if they’re not experienced in working with this material.

So much more can go wrong when your fabricator isn’t familiar with all the challenges aluminum fabrication can present. Experience and education are the only remedies for these problems, and that’s why it’s so important to choose a fabricator who’s “been there, done that” with aluminum.

At Brandywine Valley Fabricators, we carefully select materials, hire only skilled fabricators, supply them with the appropriate equipment, and subject all items to rigorous quality control inspections.

Here are a few examples of problems that can arise:

  • Choosing the Wrong Alloy:  Different aluminum alloys have varying properties. Selecting the wrong one can lead to inadequate strength, corrosion issues, or difficulties during fabrication.
  • Improper Material Storage:  Exposure to moisture, contaminants, or extreme temperatures can negatively affect aluminum’s properties and workability.
  • Distortion & Warping:  Aluminum’s thin gauge and high thermal conductivity can make it prone to warping during forming processes and cutting (especially laser cutting).
  • Surface Imperfections:  Scratches, dents, and burrs—which can easily result from improper storage and care in a fabrication facility—can ruin the final product’s aesthetics and functionality.
  • Fractures & Cracking:  Improper cutting or bending techniques can lead to cracks, which will compromise the strength and integrity of the finished product.
  • Welding Porosity:  Gas trapped within welds can create voids, which weaken the joint and make it susceptible to leaks and failure.
  • Hot Cracking:  Certain aluminum alloys are prone to cracking during the welding process because they’re not tolerant of high temperatures.
  • Lack of Fusion:  Incomplete melting and bonding between the base metal and the filler metal can create weak and unreliable welds.
  • Poor Paint Adhesion:  When oils, residues, or oxides aren’t removed from the aluminum’s surface, paint, coatings, and adhesives won’t stick (or won’t stick as well as they should).
  • Sub-Coating Corrosion:  Damaged coatings or coatings that haven’t properly adhered can lead to moisture and contaminants reaching the aluminum, resulting in corrosion.
  • Uneven Color or Fading:  Inconsistent application of paint and other protective finishes can result in uneven color or fading of the final product.
  • Improper Design:  Design flaws or inadequate consideration of stresses and loads can lead to product failure when the equipment is in use.
  • Human Error:  This is a broad subject, but mistakes made during fabrication, incorrect tool settings, or improper handling (often due to inexperience) can cause defects that present safety hazards and subpar quality.
  • Quality Control Failures:  Inadequate inspection and testing procedures can lead to undetected defects and compromised product quality.

We know what can go wrong, so we work proactively to prevent those things. That’s the Brandywine Valley Fabricators’ promise—and that’s what you can expect to get with every project.