2024 Aluminum Extrusion Design Competition Winning Entries Displayed at ET

A total of 75 entries were received in the 2024 International Aluminum Extrusion Design Competition from students and professionals from 13 countries across the globe. The entries were evaluated by Brook Massey, President of MI Metals, Inc.; Mark Butterfield, President of Manufacturing for Pennex/Metal Exchange Corporation; and Craig Werner, President of Werner Extrusion Solutions LLC. Many thanks to Almag Aluminum Inc., MI Metals, Inc., and Pennex Aluminum Company LLC for sponsoring the Student Design Competition again this year.

The winning entries for both the Student and Professional Classes of the competition were displayed at the Extrusion Showcase during ET ’24, April 30 through May 2, in Orlando, Florida. Six students received awards, including two Honorable Mentions, and three professionals received awards, including the Grand Prize.

Grand Prize - $3,500

The $3,500 Grand Prize was awarded to Ronald Boertje, Director at Dutch Innovations Systems, B.V in Barendrecht, South Holland, The Netherlands for the Topclamp Connector. The patented design developed for production by Adriaan Maris and Ronald Boertje, is an extruded aluminum component that connects square aluminum tubes flush to the Topclamp coupling or to each other. The flexible and modular nature of the system makes it suitable for high-end interior and exterior design structures including Expo stands/booths, pop-up stores, museum exhibitions, etc., according to the company.

The connector makes use of multiple advantages of aluminum extrusion, including:

  • The flexibility to easily assemble parts together by clicking and making it always fit tight when inserted into the couplings.
  • The formability to have small intricate features, shapes and openings at tight tolerances.
  • The cost efficiency by cutting the parts out of extrusion profile with automatic cutting machines.
  • The strength to withstand the force that is required for the connector.
  • The weather resistance of the aluminum alloy.
  • The ability of aluminum extrusions to have a smooth surface by anodizing making the parts move along each other without much surface resistance.
  • Using a ribbed surface to indicate what side of the connector needs to be inserted into the couplings.
  • The recyclability of aluminum alloy.
  • The easy machinability of the aluminum makes it possible to easily mill a line at the bottom of the connector to pass cables through when necessary. Also, fast and precise cutting to size.
  • The weldability of aluminum (for the Topclamp couplings).
  • The ability to have aluminum powder coated in a color and finish of choice (for the Topclamp couplings and profiles).
  • Lightweight compared to other metals.

Using TopClamp Connector

First Place Automotive / Transportation - $2,500

Founder and Creative Director for Punctuate Design in Montreal, Québec, Canada, Thibault Lerailler, won the $2500 prize for the Automotive Category for his design of the PLUS+ Extrusion electric vehicle (EV) charging station. The designer noted, "…the versatility of aluminum extrusions meets the need for an improved modular EV charging station to adapt to society’s changing lifestyles and needs."

Lerailler explained that with the Canadian government recently announcing the imminent ban of non-electrified vehicles by 2035, 4 million electric vehicles are projected to be on Québec’s roads (and more in the U.S.) by that time and that 135,000 type 2 public electric charging stations are expected to be installed in Québec alone. He noted that all existing EV charging station solutions are unsuitable or restrictive in the face of the government’s target of 35% electrification parking spaces by 2035.

Therefore, he set out to design a system that provided a larger number of shared charging terminals, which simplifies the installation and configuration of EV charging stations to better adapt to change and offers a modular and upgradeable solution.

Plus+ utilizes aluminum extrusions' advantages to cater to the rapid electrification of the future’s parking lots. The concept comes as a family of easily assembled and disassembled building blocks to configure the ideal urban installation: the assembly modules in a plus (+) shape allowing extrusion connections within four axes. His design of an extrusion rail, assembly module, and accessories can be spread out in a flexible layout that can adapt to different parking spaces – from linear to front-to-front, to narrow interior parking with walls to exterior parking lots requiring light or shade.

The electrical feed comes first from the panel installed in the master pedestal, then it travels through the aluminum extrusion(s) to power up to six chargers or electrical accessories. Groups can be multiplied to accommodate any parking layouts and configurations - reducing the need for demolition and construction to add electricity feeds when the need for EV charging pods multiplies in the future.

The extrusion is composed of Alloy 6063, used for its heat-treated characteristics and good strength, corrosion resistance, formability, machinability and weldability. Three class III hollow profiles were designed with standard tolerances, with a class I architectural anodized finish best suited for outdoor applications. The shape has medium-sized circumscribing circles, a uniform thickness of 3.5 mm all around, rounded transitions and corners, and follows a 2-axis perfect symmetry, making it economical to manufacture and suited for most standard extruders, noted the designer.

First Place Architectural - $2,500

Nikolaos Karintzaidis, architect from Studio Niko Kapa, won the Architectural Category with his design of the "ARC Motorized Bioclimatic Pergola".

The designer explains, "Functionality defines aesthetics, using new techniques to reinterpret
eternal themes in an attempt to synthesize spatial quality through specific architectural gestures. The main structure is comprised of slender aluminum framework, supporting a transformative canopy that can switch between a flat ceiling and a vaulted conformation. On this structure, [a] series of curved components are supported in order to define protected and comfortable outdoor areas with style and elegance."

Niko goes on to explain, "Completely made of aluminum, the bioclimatic pergola lets occupants to adjust the level of natural lighting and air circulation, enabling them to enjoy the beauty of landscape in the greatest climate comfort. Ceiling composition filters light through during daytime, creating a relaxing and reflective atmosphere for users."

LED lights are integrated into the fins, the aluminum sunshades or "fins" are adjustable with a rotation angle of 0 to 120 degrees, there is a perimeter channel for water collection integrated with a vertical drain, and the canopy is motorized for easy deployment. The ARC system can be self-supporting or can be wall mounted and further personalized through a range of colors and finishes. "Pairing modules permit dimensional variations and different assemblages, since these can be grouped together in various ways to fit myriad spaces," stated the designer.

ARC offers numerous possibilities to align with the architecture and surroundings, with applications ranging from private homes as well as public environments, such as hotels, restaurants, cafes and outdoor working and recreation sites, he explained.

"Combining modern design with simplicity of shape, curves and crisp lines define a layout adjusting elegantly into any architectural context while permitting occupants to enjoy outdoor spaces regardless of weather conditions all year round," Mr. Karintzaidis stated.

Thank you to the 2024 Student Aluminum Extrusion Design Competition Sponsors: