Extrusion Trim & Accessories
Most extrusions are hidden away from the vehicle owner's touch and sight. Not these parts. These roof racks, sunroofs, running boards and bed extenders are intentionally purchased to improve their vehicle experience. It's about personalization. About utility. It's about access, enabling the whole family to get up into a pickup or a large SUV. Having the direct consumer interaction, their testimonials say a lot about the value of extrusions in these products:
"… are durable, stylish and constructed with cutting-edge polymers mated to a recessed extruded aluminum frame. The result is super-strong bars that are virtually corrosion-free."
"Aluminum is lightweight but with high strength, it is corrosion and wear-resistant."
"Rugged aluminum construction adds corrosion resistance as well as a lightweight product for easy handling."
On roof racks, "It is easy to be assembled, unlike like steel racks which need to be welded in advance. The light weight of extruded aluminum roof rack uses less fuel."
Running Boards & Tailgates
Pickup trucks stand high off the ground, and even for a six-foot tall man, the running boards are used regularly. Imagine how essential they are for shorter men, women and children. They are a make-or-break product; without them, the family would not be using the truck very often.
In addition to the utility of the running board, the suppliers and OEMs have paid close attention to durability and appearance. A truck or SUV with running boards still looks good. The premium models go a step further by including a power-assisted running board that is positioned out and ready to be used when the door opens, yet then moves back underneath the vehicle in driving mode.
Design Perspectives
The function of a running board is well-understood, yet from a product design perspective, let's look at the reasons aluminum extrusions are commonly used:
- Corrosion resistance: Running boards are exposed to road salts and impact of rocks. The inherent corrosion resistance of aluminum makes it a great selection.
- Product length and straightness: Running boards can be as much as 2 meters long, which is not an issue for an extrusion, and they need to be straight.
- Built-in features: With extrusions, it is easy to include raised ledges for grip, and other features to adhere plastic end caps and covers.
Design versatility
Design versatility is another reason aluminum extrusions are commonly used. Aluminum extrusions can be produced in nearly any shape that helps in the function of a step, and is torsionally stiff, is aerodynamic, lightweight, and open to creative design.
Surface finishes
Surface finishes are yet another reason why aluminum extrusions are ideal. Aluminum extrusions are versatile in that it is easy to mount rubber or plastic hardware for aesthetics, end caps, or for grip. They also can be powder coated, chromed, wet-painted, polished, or anodized to deliver the look that you desire.
Aluminum extrusions are lightweight: Weight is the enemy of efficiency, so for all of these products, it is advantageous that the primary structure be a thin wall aluminum extrusion. Weight is even more critical for the powered running boards as they move in/out with a small electric motor. The heavier the board, the larger, heavier, and costlier the motor package.
Tailgate
General Motor’s engineering teams have determined how to bring more value to a common component, the tailgate. This 6-function Multi-Pro™ tailgate allows easier access, offers a guard to block payload from falling out, like a bed extender, and can function as a work surface. It even features electrical plugs and speakers for tailgating.
Here, we highlight the aluminum extrusion used on the step. Note the raised ribs that help in slip resistance, and the integral holes for a threaded attachment on the end caps.
Extrusions Align to the Customer Needs in Tailgate
- Stiff & strong for secure load
- Ease of assembly & integration
- Rib profiles for slip resistance
- Great appearance, painted or anodized
- Corrosion resistant
- Lightweight to offset additional mechanisms
On the Roof
Look up! To further enhance the value of the vehicle, and maximize its utility, we want to take advantage of the space on the top of the vehicle. Roof racks help consumers carry bikes, luggage, skis, kayaks and even set up a camping tent.
Roof racks are commonly found on dealership lots, often colored black to blend in. Extrusions are a natural fit for this application because the rack sections need to be long, straight, good looking, and easy to integrate to the vehicle, and to the payload.
Roof Racks Designed to Fill Customer Needs
For the number of OEM-specified roof racks or pickup bed racks, there are multiples more available in the aftermarket. There too, extrusions are the primary design material, described by THULE as a "durable, corrosion resistant aluminum construction."
Extrusions align to the customer needs in roof racks:
- Stiff & strong for secure load
- Ease of assembly & integration
- Versatility in profiles, in mount design
- Great appearance, painted or anodized
- Corrosion resistant
Bed Extenders
Americans love pickup trucks. Trucks have power, a comfortable ride, and a bed to carry stuff. Sometimes the bed is not long enough, and they need a bed extender. The tailgate is down, the construction materials or motorcycle or snowmobile are in the bed, held securely on the back by this lightweight "fence." When the extender is not needed, it is removed and put away.
Like roof racks, these bed extenders are often made with extrusions. They are strong and stiff through efficient design; low in weight, and they can be painted, chromed or anodized. It is easy to integrate the end connections, and the low weight also makes them easy to remove when not in use. Bed extenders are offered by OEMs with considerable support in the aftermarket.
Cargo Bars
The new electric vehicles are coming with many thoughtful features to enhance the value and utility of the vehicle. Rivian’s Cargo Bar is a good example of a well-engineered product with connectors that enable it to be used both in the bed and on the roof. In addition, the bars slide on an extrusion that enable the length to be easily adjusted to the width of the roof, and the bed. The same product works for both the R1T pickup and the R1S SUV.
Sunroofs
Sunroofs were once a luxury, yet are now available on many vehicles from sedans to minivans to pickups. With the push of a button, the roof is open to fresh air. The roof window glides quietly rearward between the roof and headliner, thanks to the smooth surface finish of the extrusion profile that makes up the window surround. Fresh air and sunlight come in, yet when the window is closed, rain, snow, wind and road noise are kept out. The tight profile extrusions provide the critical interface structure on the side rails.
Extrusion-based result
- 6 pieces only: 2 extrusions + 4 small aluminum stampings
- 20% weight savings
- Cost neutral with investment reduction for volume
- 22-piece part reduction
- Reduced labor cost
Panoramic Windows
The latest trend on a number of vehicles, including Tesla S, are large panoramic windows. The size is enormous, covering almost the entire roof. The entire glass surround may be one large stamping yet expect to see extrusions for the detailed sunroof mechanism profile for all the reasons stated above.
Aftermarket Lighting
Light Bar
Aluminum extrusions proved to be the ideal material for a long, roof-mounted light bar. To the serious off-road racer or enthusiast, traveling rugged country at night, great lighting is invaluable. The challenge of lightbar construction is a lightweight material that manages the heat of the high-output LED’s, and is formable, maintains shape after tight tolerance machining, and is durable in the field. The 6360-T6 aluminum extrusion has proved to be a great choice.
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