Tube Size Chart

Choosing the Right Tube Size for Aluminum Fabrication

At Testrite Aluminum, we supply raw aluminum tubing to professionals who fabricate in-house. Our customers include CNC shops, fixture manufacturers, SEG frame builders, and event production teams. These professionals buy aluminum tubing in bulk and cut, miter, and assemble it themselves using shop tools.

Choosing the correct tubing size is a critical step in any project. The outer diameter and wall thickness determine how a tube performs under load, whether it will telescope smoothly, or whether it can accommodate specific brackets or internal supports. Since we do not sell pre-cut or assembled components, proper size selection is the foundation for a successful build.

Our clients value the flexibility that comes with raw materials. They aren’t looking for kits or pre-fabricated systems. They want control over design, over measurements, and over the final product.

Understanding Our Tube Size Chart

Our tube size chart provides key specifications for every aluminum tubing product we offer. It includes outer diameter (OD), inner diameter (ID), and wall thickness. These dimensions enable fabricators to select tubing that fits precisely with their existing hardware or project requirements.

The chart is handy for professionals who build SEG frames, machine industrial parts, or construct displays. Proper sizing ensures structural compatibility and reduces material waste. For a closer look at SEG frame use cases and layout strategies, explore our SEG Frames blog.

Because we only offer raw material, understanding sizing is essential. There is no cutting, threading, or assembly done before delivery. You select the profile, and we provide it as-is, ready for you to fabricate.

Round Aluminum Tubing Options

Round aluminum tubing is a versatile option used in telescoping applications, support poles, signage structures, and mechanical assemblies. Testrite Aluminum offers round tubing in a variety of diameters and wall thicknesses to meet different structural and functional needs.

When telescoping is required, accurate sizing is essential. Our tube size chart helps identify which outer and inner diameters will nest together correctly. This is especially important for adjustable displays or mobile frames, where stability and movement are both factors.

We provide round tubing in straight, raw lengths. Customers are expected to handle all cutting and finishing using appropriate tools, such as chop saws with non-ferrous blades. Review our aluminum round tubing collection to see available sizes and details.

Square and Rectangular Tubing Dimensions

Square and rectangular tubing are widely used in SEG frames, modular display systems, and structural projects requiring flat, clean lines. These profiles allow for precise corner alignment and bracket compatibility, making them ideal for rigid frame construction.

Our square tubing is offered in multiple wall thicknesses and sizes to match project load demands and design specifications. Rectangular tubing provides added directional strength and is often selected for SEG applications that require the frame to sit flush against a wall or surface.

These profiles pair well with SEG extrusions when correctly matched. Browse our SEG frame extrusion collection to find compatible profiles. Each listing includes specs to help you ensure a proper fit with your selected tubing.

Heavy Wall Tubing for Industrial Applications

Heavy-wall aluminum tubing is designed for industrial use where extra strength and durability are required. These thicker-walled tubes are ideal for CNC machining, mechanical parts, and structural applications that demand secure mounting and high load capacity.

The added material enables deeper threading, stronger connections, and a higher tolerance to stress. While not ideal for telescoping applications, heavy-wall tubing performs well in static frames, custom jigs, and load-bearing components.

As with all our materials, heavy-wall tubing is delivered raw and uncut. Fabricators use their own equipment to cut, tap, and integrate each piece into a final assembly. Reviewing the size chart before ordering helps ensure you select the correct thickness and diameter for your application.

Matching Tubing with SEG Frame Extrusions

SEG frame builds require precise sizing and compatibility between tubing and extrusion. At Testrite Aluminum, we provide both. Fabricators can source square or rectangular tubing that matches their extrusion profile and customize it in-house for their display or frame system.

Our tubing options are commonly used by companies building retail displays, event structures, and graphic frames. Proper tube size selection is crucial for achieving clean corners, stable support, and seamless integration with brackets and accessories.

Each extrusion listing includes notes on compatible tube sizes. Always confirm internal and external dimensions using the product descriptions and our size chart to avoid mismatch and rework.

Tools, Cutting, and Assembly Guidelines

Testrite Aluminum serves professionals who have the tools and experience to fabricate on-site. Our tubing is not pre-drilled, pre-finished, or assembled. The customer must do all fabrication.

For clean, accurate cuts, we recommend using chop saws or miter saws with non-ferrous blades. This reduces burr and keeps tubing ends clean and square. When building square or rectangular frames, mitering must be precise to ensure flush corners.

Drilling and tapping are often part of the process. Thicker tubing allows for threaded connections, while thinner-walled tubes may require rivets or press-fit accessories. Always dry-fit components before final assembly.

Why Fabricators Choose Testrite Aluminum

Professionals across various industries choose Testrite Aluminum for a reason: we offer raw aluminum tubing with the precise dimensions, consistency, and clarity required for fabrication. Our customers know exactly what they’re getting, and they have the skill and equipment to transform it into custom frames, fixtures, or mechanical parts.

We focus on raw materials. No pre-cuts. No kits. High-quality extrusion, ready for your tools and specifications. Whether you're building SEG frames, modular structures, or prototypes, Testrite Aluminum provides the tubing professionals trust.

Frequently Asked Questions About Tube Size Chart

What is the difference between tube size and pipe size in aluminum materials?

Tube size refers to the actual measured outer diameter (OD) and wall thickness of the tubing, which is critical for fitting, telescoping, and structural use. Pipe size, on the other hand, is typically based on nominal measurements and refers more to fluid-carrying capacity rather than structural dimensions. Aluminum tubing, especially for fabrication or frame building, is most often specified using accurate dimensions from a tube size chart, not nominal pipe sizes.

Can aluminum tubes from a size chart be used interchangeably with steel tubing sizes?

Not always. Although some outer diameters may match between aluminum and steel, the wall thickness and strength properties are different. Aluminum is lighter and less dense than steel, so substitutions require structural calculations. Always check both the mechanical properties and dimensions from the aluminum tube size chart before attempting cross-material compatibility.

Are metric sizes included in a typical aluminum tube size chart?

Most tube size charts in the U.S., including those from Testrite Aluminum, list sizes in imperial units (inches and fractions of an inch). Metric sizing is used more commonly in European or international manufacturing. If a project requires metric tubing, conversion from the imperial system must be precise, especially for telescoping or press-fit applications.

How do I determine the correct wall thickness using a tube size chart?

To determine the correct wall thickness, first identify the intended load, structural requirements, and connection type. A thicker wall increases strength and allows for threading or tapping, while a thinner wall reduces weight and is suitable for non-load-bearing or telescoping use. Use the tube size chart to compare the outer diameter, inner diameter, and wall thickness according to your design criteria.

Can the tube size chart assist in selecting compatible accessories, such as caps, connectors, or inserts?

Yes. Many accessories are manufactured to match standard tubing sizes. Using a tube size chart ensures that caps, plastic inserts, corner connectors, and brackets will fit snugly. However, accessory fit also depends on wall thickness and internal clearance, so it’s essential to match accessories to both the outer and inner diameter values.

Is the tolerance information included in a tube size chart?

Standard tube size charts typically provide nominal sizes but do not always include tolerance ranges. Tolerances are crucial for precise fits, especially in telescoping or CNC applications. For detailed tolerance data, consult the product-specific technical documentation or request this information from the supplier before fabrication.