Aluminium windows are widely recognized for their elegance, durability, and energy efficiency, making them an ideal choice for both residential and commercial properties. But have you ever wondered about the process behind creating these high-performance windows? From initial design to final installation, aluminium windows go through a meticulous production process. In this guide, we’ll walk you through each stage of manufacturing, shedding light on the craftsmanship and technology involved.
Step 1: Design & Custom Measurement
The creation of aluminium windows begins with a detailed consultation between the manufacturer and the client. During this initial meeting, key aspects such as the style, size, and functionality of the window or door are discussed. Precise measurements are taken to ensure the final product fits seamlessly into the intended space. The design phase also includes decisions regarding colour, shape, glazing options, and additional features. This collaborative process ensures that the final design matches the client’s vision, while also considering the manufacturer’s recommendations for optimal performance.
Step 2: Aluminium Extrusion
Once the design is finalized, the next step is extrusion — the process that shapes the aluminium profiles. Aluminium billets are heated to temperatures between 375°C and 500°C, making the metal malleable. The softened aluminium is then forced through a die, creating profiles such as frames, sashes, and mullions. This extrusion process allows for the precise fabrication of custom aluminium window profiles, tailored to the specific requirements of the project.
Step 3: Powder Coating for Durability and Aesthetic Appeal
To enhance the appearance and longevity of the aluminium, the profiles undergo a powder coating process. This begins with cleaning and pre-treatment to ensure proper adhesion of the powder coating. The aluminium profiles are then coated in a specialist powder coating booth and cured in high-temperature ovens. This method offers a durable, long-lasting finish in a wide range of colours, with excellent resistance to fading, chipping, and corrosion. The result is an aluminium window that combines both aesthetic appeal and robust protection against the elements.
Step 4: Thermal Insulation with Polyamide Thermal Break
Energy efficiency is a top priority for modern aluminium windows. To minimize heat transfer, profiles are equipped with a thermal break made from polyamide, a material that enhances insulation by creating a barrier between the interior and exterior metal components. This innovative thermal break technology not only improves energy efficiency but also allows for the option of two-tone finishes — different colours on the interior and exterior surfaces of the window or door.
Step 5: Cutting and Punching the Profiles
With the aluminium profiles prepared, the next step is to cut them to the specified lengths. Each profile is precisely cut to match the client’s exact measurements for their custom window or door. Punching machines are then used to create holes, slots, and other necessary openings for hardware installation, ensuring that all components fit together perfectly during assembly.
Step 6: Assembly and Hardware Installation
The assembly of aluminium windows and doors involves joining the individual components — such as the frame, sashes, and mullions — using precise mechanical techniques. This may include butt joints at right angles or 45-degree angles. The window or door is then fitted with seals, weatherstripping, and necessary hardware, such as locks and hinges, ensuring that the final product is both functional and secure. This stage is crucial for ensuring the tightness, durability, and overall performance of the window or door.
Step 7: Glass Installation
With the window or door frame assembled, the next step is to install the glazing. Depending on the client’s preferences, the glass may be double or triple-glazed, with options for energy-efficient Low-e coatings and sound insulation. The glass is securely held in place with gaskets, silicone sealants, or other materials designed to ensure a tight, weather-resistant seal.
Step 8: Rigorous Quality Control
Each aluminium window and door undergoes a rigorous quality control inspection before leaving the manufacturing facility. This ensures that all design specifications are met and that the product performs to the highest standards. Inspections typically focus on areas such as the airtightness of seals, durability of the powder coating, and overall functionality of the hardware. Simulated usage tests are often conducted to verify performance under real-world conditions.
Step 9: Packaging for Safe Delivery
To protect the finished windows and doors during transportation, they are carefully packaged using protective materials and enclosed in custom wooden crates. This ensures that each product arrives at its destination in perfect condition, ready for installation.
Why Choose Aluminium Windows?
Aluminium is not only a highly durable and low-maintenance material, but it is also environmentally friendly. The manufacturing process requires less energy than other materials, and aluminium is 100% recyclable. At LEDOW, we are committed to delivering top-quality, custom aluminium windows and doors that are as sustainable as they are beautiful. Our dedication to precision and craftsmanship ensures that every product is tailored to your specific needs, delivering both style and performance.
