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Using Aluminum Extrusion to Meet the Challenges of Tomorrow’s Vehicles

Available On-Demand Until: October 18, 2019

Click HERE to find the start time at your location

In the past five years, the aluminum extrusion content in the average North American auto or light truck has increased by nearly 50%, to about 40 pounds per vehicle.  Today extrusions are found in a wide range of applications – from crash management systems, to structure, to trim – with an equally wide range of performance requirements. 

But the needs of future vehicles are rapidly evolving as demand for ongoing efficiency drives further light-weighting, while EVs and autonomous vehicles move toward center stage. How can the product designer utilize extrusion to meet the challenges of tomorrow’s vehicles?
This 60 minute webinar will review the thermomechanical extrusion process – since it’s the process that drives component performance – and then explore how extrusions will play an important role in ongoing safety improvements and in vehicle electrification.


Rob Nelson, Almag Aluminum

Rob Nelson is VP, Sales & Marketing for Almag Aluminum of Brampton, Ontario, and an active member of the Aluminum Extruders Council’s Automotive Team. An engineer by training, Rob works with Almag’s automotive customers on applying extrusions in new vehicle designs. He brings a strong materials experience to the task, having spent much of his career working in the automotive market with a leading steel company before joining Almag several years ago. Rob has a bachelor’s degree in engineering technology from McMaster University and a degree in mechanical engineering from Fanshawe College.

Ben Kuhn, Almag Aluminum

Ben Kuhn graduated from McMaster university with a bachelor degree in Automotive Engineering and a Technical Business Diploma from Mohawk College. He worked as an Automotive Engineer for two-and-a-half years designing advanced mechanisms. Mr. Kuhn then joined the Almag team, and the aluminum extrusion industry, in June of 2016 as a project manager. His tasks were to use technical thinking and communication skills to help with the successful onboarding and production of high-end commodity business. Using his past design experience and his growing knowledge of extrusion, he works with customers and potential customers to proactively develop long term, cost effective solutions. In November of 2017, he was promoted to Territory Sales Manager, where he continues to foster existing customer relationships and seek out partnerships where he and his company can provide mutually beneficial products.


Lisa Arrigo, SAE International

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  • Alloy selection and modification
  • Profile design guidelines
  • The physics & metallurgy underlying the extrusion process
  • Fabrication
  • Joining extrusions with other materials
  • Joining extrusions with aluminum
  • Applications & Case Studies
  • Crash management
  • Chassis and structure
  • Interior
  • Body, trim
  • Steering, brakes, suspension
  • Electronics
  • Noise, vibration, harshness
  • Electrification
  • Other