- Design for Manufacturability (DFM): Consult the extruder early. Use standard alloys (6063). Maintain uniform wall thickness. Use generous radii. Avoid unnecessarily tight tolerances.
- Modify an Existing Die: Ask if a similar profile exists; modifying an old die is cheaper than a new one.
- Optimize the Cross-Section: Minimize the circumscribing circle size and weight per meter without compromising function.
- Increase Order Volume: Larger, consolidated production runs reduce setup costs per part.
- Simplify Finishes: Mill finish is cheapest. Standard anodizing colors (clear, black) are cheaper than special colors.
- Relax Tolerances: This can dramatically improve yield and reduce cost.
- Consider Alternative Processes: For very low volumes, see if the part can be made from a standard profile plus machining, which may avoid a die cost entirely.