Key Takeaways:
- Material Variety: Aluminum tubing is available in various shapes, wall thicknesses, and finishes, providing flexibility for both structural and display projects.
- Fabrication Focus: Products are shipped as raw material, requiring professional cutting, assembly, and tooling by the buyer.
- Use-Specific Selection: Choosing the right tubing depends on application type, load requirements, and compatibility with brackets or telescopic systems.
Aluminum tubing is a foundational material across a wide range of professional industries. From retail display frames and modular structures to CNC-machined components, aluminum tubing offers the strength, lightweight properties, and versatility that modern fabrication demands. Companies that build in-house rely on raw materials they can cut, miter, and finish based on exact project requirements. Pre-packaged or assembled parts often fall short of the precision and flexibility professionals need.
Testrite Aluminum is a U.S.-based aluminum supplier with more than 100 years of manufacturing experience. We do more than stock aluminum. We provide fabrication-ready materials that meet the standards of professionals. Our facility supplies precision tubing used by display manufacturers, digital printers, CNC machinists, and structural fabricators. Our products support teams who prefer full control over cutting, drilling, and assembly.
In this piece, we will be discussing what aluminum tubing is, how it’s made, the types available, and how to choose the right tubing for your specific fabrication needs.
For Custom Fabricators: Why Raw Aluminum Tubing Matters
Professionals who build their own SEG frames, retail displays, or structural components understand the importance of sourcing the right raw materials. Testrite Aluminum supplies bulk raw aluminum tubing, intended for companies that fabricate in-house using their own cutting, mitering, and assembly tools.
This approach gives you full control over dimensions, finishes, and fit. If you're working with round tubing for telescopic structures or using heavy-wall tubing for CNC machining, raw aluminum provides flexibility and compatibility with custom processes.
For those seeking fully fabricated frames that require only final assembly, Testrite Visual is the better fit. But if you’re cutting and assembling your own builds, TestriteAluminum.com is tailored to your needs.
None of our tubing or extrusions is pre-cut, pre-drilled, or shipped with hardware. They are made for professional fabricators. To work safely and efficiently, we recommend using appropriate saws and blades designed for non-ferrous metals, as well as wearing proper personal protective equipment.
What Is Aluminum Tubing?
Aluminum tubing is a hollow, cylindrical, or square extrusion made from aluminum alloys, designed for structural, display, and functional applications. It's widely used across industries where a balance of strength, weight, corrosion resistance, and machinability is essential.
Unlike finished products, the tubing available through TestriteAluminum.com is raw material. It’s provided in full lengths, with no pre-cutting, pre-drilling, or hardware included. This allows professional fabricators to integrate it seamlessly into custom builds using their own tooling and production standards.
Testrite offers a variety of sizes and wall thicknesses to support everything from light-duty framing to heavy-load structural assemblies. For example, fabricators who require telescopic compatibility often choose our 1" OD x.038" Wall Round Aluminum Tubing, which provides an ideal fit for nested designs.
Similarly, when strength and wall integrity are priorities, the 1-1/2" OD x.058" Wall Drawn Round Aluminum Tubing offers enhanced rigidity, making it suitable for industrial or CNC-machined components.
Aluminum tubing differs from aluminum pipes in that tubing is typically defined by its outer dimensions and used for structural purposes. In contrast, pipes are often used for fluid transfer and are measured by their internal diameter. That distinction becomes important when choosing the right material for custom fabrication.
What Is Aluminum Tubing Made Of?
Most aluminum tubing is made from 6063 or 6061 aluminum alloys, which are prized for their exceptional strength-to-weight ratio, excellent corrosion resistance, and workability. These alloys are ideal for applications that require precision cutting, mitering, and in-house fabrication.
At Testrite Aluminum, we supply extruded and drawn tubing designed for professional use. For example, our 1" Square Aluminum Tube with Single Slot is made from 6063-T5 alloy and provides an ideal balance of strength and machinability. It's commonly used by display fabricators and manufacturers who build internal structures, product stands, or modular frames.
For structural or telescoping builds, aluminum tubing is often heat-treated and tempered. An example is our 1-1/2" OD Drawn Round Tubing, which uses 6063-T832, a heat-treated alloy known for dimensional consistency and increased durability.
In our round aluminum tubing collection, you’ll find a variety of options suited for telescopic, telescoping, or static structural designs. These extrusions are commonly used in trade show exhibits, signage structures, and telescoping poles.
For applications requiring more surface area or slot compatibility, the square telescopic tubing options offer enhanced modularity, while rectangular tubing profiles support low-profile framing solutions.
Professionals working on multi-part or extendable systems may also find what they need in our telescopic tubing collection, which features compatible outer diameters and walls for nesting parts.
How Is Aluminum Tubing Made?
Aluminum tubing is typically produced through two main processes: extrusion and drawing. Each method delivers specific characteristics that align with the structural or fabrication needs of the end user.
Extruded Aluminum Tubing
Extrusion involves forcing heated aluminum billets through a shaped die, which forms a continuous profile with consistent dimensions. After extrusion, the tubing is cooled, straightened, and cut to full lengths.
Testrite Aluminum offers extruded tubing suitable for lightweight builds and custom fabrication. For example, the 1" OD x .038" Wall Round Aluminum Tubing is a popular choice for display manufacturers and structural frame fabricators who need telescopic compatibility.
Drawn Aluminum Tubing
Drawn tubing begins as an extruded product and is then pulled through a die to refine its shape further. This results in improved strength, tighter tolerances, and more consistent wall thickness. These characteristics are especially valuable for telescoping systems or precision-machined components.
The 1-1/2" OD x .058" Wall Drawn Tubing is a strong example of this, offering enhanced rigidity for demanding industrial or CNC applications.
Finishing and Fabrication Readiness
Some tubing is anodized after forming to improve surface durability and resistance to corrosion. Testrite offers silver anodized options that are ideal for in-house cutting, slotting, or mitering. These finishes also enhance the professional appearance of completed structures.
All tubing sold through TestriteAluminum.com is delivered in full, uncut lengths. No hardware or pre-assembly is included. Fabricators should use saws specifically designed for aluminum and non-ferrous metals, along with the proper use of personal protective equipment.
What Are the Types of Aluminum Tubing?
Aluminum tubing comes in a variety of shapes and wall thicknesses, each serving specific functions in different industries. Understanding these types helps fabricators choose the right material for both structural and aesthetic requirements.
Round Aluminum Tubing
Round tubing is the most common form and is frequently used in telescoping systems, structural frames, and display stands. Its uniform shape offers consistent strength in all directions, which makes it well-suited for applications that involve movement, weight-bearing, or frequent handling.
This type is especially popular among digital printers, display manufacturers, and construction fabricators who build support frames, product risers, or transportable structures. Round tubing is also easier to rotate or telescope, making it a good fit for adjustable height designs.
Square Aluminum Tubing
Square tubing offers a clean look and a flat surface ideal for mounting or attaching brackets and accessories. The symmetrical shape provides greater stability when used in frames, corners, or modular assemblies. Because of its consistent dimensions, it is commonly used in SEG framing, retail displays, and internal structural supports.
The availability of slotted square tubing also provides a channel for accessories or panel inserts, which reduces the need for custom cutting or complicated joins.
Rectangular Aluminum Tubing
Rectangular tubing is often used when space constraints or a low-profile design are essential. Its flat surfaces and differing side dimensions make it ideal for horizontal frames, support rails, and structures that require more surface contact. This type is frequently selected by fixture fabricators or those working in tight spaces where a round or square profile may not fit as efficiently.
Heavy Wall and Telescopic Tubing
Heavy-wall tubing features thicker walls for increased strength, making it ideal for CNC machining, industrial fabrication, or applications that require load-bearing performance. These tubes maintain their structural integrity under stress, which is especially important for manufacturers who mill or modify the material after purchase.
Telescopic tubing is designed to nest cleanly within other tubes of compatible size, offering flexibility in extendable builds. These are commonly used in adjustable signage, extendable arms, and modular fixtures. Proper fit and tolerance are essential for smooth sliding, and drawn tubing is often selected for these applications due to its consistency.
What Is Aluminum Pipe Used For?
Although often used interchangeably in casual conversation, aluminum pipe and aluminum tubing serve different purposes, especially in professional fabrication. The key distinction lies in how they are measured and applied.
Aluminum pipe is typically defined by its inner diameter and is primarily used for fluid and air flow systems. It’s designed to transport materials, which means its strength and performance are centered around pressure containment rather than structural framing.
Common use cases for aluminum pipe include:
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Pneumatic and hydraulic systems in manufacturing settings
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Conduit for wiring or cabling in architectural or commercial construction
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Ventilation and ducting systems where corrosion resistance is needed
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Irrigation systems that require lightweight, non-corrosive piping
While tubing is typically structural, pipe is functional in the sense of directing substances or acting as a protective channel. That’s why tubing is generally preferred by companies building frames, displays, or telescoping parts, while pipe is reserved for plumbing, air systems, or custom mechanical builds.
It’s important not to substitute one for the other without fully understanding the dimensional and functional requirements of your application. Tubing is measured by outer diameter and wall thickness, which allows for tighter structural tolerance and compatibility with connectors or brackets. Pipe, measured by schedule and nominal size, does not always offer the same fit.
Selecting the Right Tubing for Your Project
Choosing the right aluminum tubing starts with understanding the specific demands of your build. Since Testrite Aluminum supplies the raw material, the final performance of your project depends on how well the tubing matches your application and how precisely it is fabricated.
Determine the Structural Load and Use Case
Start by determining the amount of stress the tubing will need to withstand. For static display frames or signage, lightweight round or square tubing may be sufficient. For heavier builds, such as CNC-machined components or load-bearing structures, a thicker wall or drawn tubing is more appropriate.
Consider whether your project requires fixed-length parts or adjustable, telescoping sections. Telescoping builds need tight outer diameter tolerances and consistent wall thicknesses to ensure smooth nesting.
Select the Appropriate Shape
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Round tubing is ideal for telescoping, adjustable-height systems and cylindrical designs.
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Square tubing provides flat surfaces and cleaner corners, which are helpful for display edges or modular framing.
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Rectangular tubing is ideal for low-profile or space-constrained layouts.
Choosing the correct shape also affects how easily you can mount accessories or make cuts and joins.
Consider Fabrication Tools and Finish Needs
Testrite Aluminum tubing is intended for professionals who cut, miter, and machine aluminum in-house. The tools you use will impact not only safety, but also the quality of the final product. Use saws designed explicitly for non-ferrous metals, and always follow the guidelines for protective equipment.
If the material will be visible or exposed to the elements, an anodized finish may offer both aesthetic value and improved resistance to corrosion.
Check Compatibility With Accessories
Before selecting tubing, review the specific product description to confirm compatibility with your intended hardware, brackets, or connectors. Testrite provides detailed product specs to help match tubing sizes and wall thicknesses with accessories. Since these are raw materials, you are responsible for ensuring that everything fits together according to your fabrication plan.
Your Source for Aluminum Tubing
Testrite Aluminum supplies raw, fabrication-ready tubing for professionals who build in-house. Our catalog includes round, square, and rectangular profiles in a range of sizes and wall thicknesses. All tubing ships in full lengths, with no pre-cutting or hardware, allowing full control over cutting, assembly, and finish.
We serve fabricators who demand precision, consistency, and compatibility across projects. Whether you're designing display frames or structural components, we provide the materials that support custom fabrication from start to finish.
Final Thoughts
Aluminum tubing plays a critical role in structural design, modular systems, and custom fabrication. Understanding the differences between tubing types, alloy compositions, and manufacturing methods helps professionals make informed decisions for their specific applications.
Testrite Aluminum is built for fabricators who want full control over their production process. With a wide selection of raw, fabrication-ready tubing in round, square, and rectangular profiles, we support teams that cut, miter, and assemble in-house.
Whether you're designing SEG frames, constructing structural builds, or machining precision components, Testrite Aluminum provides the consistency, quality, and dimensional accuracy required to meet your project standards.
Read also:
- Build Fast with 1" Square Tubing and Press‑Fit Plastic Corners
- Custom Powder Coated Aluminum Tubing
- Why Retailers Prefer Testrite’s 1” OC Aluminum Slatwall
Frequently Asked Questions About Aluminum Tubing
What is the difference between aluminum tubing and conduit?
Aluminum tubing is typically used for structural or framing applications, while conduit is designed to house electrical wiring and is often regulated by building codes.
Can aluminum tubing be welded, and if so, what method is recommended?
Yes, aluminum tubing can be welded. TIG (Tungsten Inert Gas) welding is commonly used due to its control and cleanliness, especially for thinner-walled sections.
Does aluminum tubing need surface treatment before painting?
Yes, surface preparation such as cleaning, degreasing, and light sanding or etching is recommended to ensure proper paint adhesion to aluminum tubing.
Can aluminum tubing be bent without cracking?
Some aluminum tubing can be bent, but the ability to bend depends on the alloy and temper. Softer grades, such as 6061-T6, are harder to bend without annealing.
What’s the typical length of aluminum tubing supplied?
Most aluminum tubing is supplied in standard full lengths, usually 12 feet or longer, depending on the supplier. Custom lengths require on-site cutting.
How does aluminum tubing perform in outdoor environments?
Aluminum is naturally corrosion-resistant, and anodized finishes enhance its durability outdoors. However, marine or high-salt environments may still require additional protection.
Is aluminum tubing safe for food-related or hygienic applications?
Certain aluminum alloys can be used in food equipment; however, tubing used in sanitary environments must meet specific certification and surface finish standards.
Can aluminum tubing support heavyweight loads?
Yes, especially heavy-wall or drawn tubing. The load capacity depends on the diameter, wall thickness, span length, and the method of support or connection.
Does aluminum tubing expand or contract when subjected to temperature changes?
Yes, aluminum has a relatively high thermal expansion coefficient. Dimensional changes can occur with temperature swings, which should be accounted for in precision builds.
What are common connection methods for aluminum tubing?
Fabricators commonly use mechanical fasteners, press-fit connectors, adhesive bonding, or welding, depending on the structural needs and finish requirements.
