The steel trusses supporting Gatwick Airport's new station concourse are clad in gold anodised aluminium.

N700S-8000 Shinkansen high-speed train, developed by Japan Railway Company, features extruded aluminium bodywork. The nose consists of 32 plates welded together and strengthened glass window. The metalwork is topcoated with fluoroethylene vinyl ether (FEVE), a tough long lasting fluoropolymer created for demanding exterior applications.

Injection over-moulded die cast aluminium for a Hilti power tool gearbox body. The aluminium is cast and de-burred, and the polyamide (PA-GF30), nylon, is over-moulded in-line using a fully automated process developed by Frimo.

TRÆ in Aarhus, Denmark, is built in part from reused construction waste. Designed by Lendager Architects for Kilden & Hindby and PFA Ejendomme, in collaboration with MOE Consulting Engineers and Kaj Ove Madsen, Aarhus Municipality and Realdania, it is due to be completed 2024. Reuse and recycling innovations in the facade include the use of decommissioned composite wind turbine blades for solar shielding, aluminium roof plates for the facade, wooden cassettes, wood insulation, low-carbon concrete and insulation from waste textiles. The reused aluminium facade comes from two different renovation projects, where they had been discarded, plus water-damaged panels from a supplier. Standing 78 m high, the structure is steel, concrete and timber. All materials have been thoroughly tested so that they continue to meet the requirements and regulations.

TRÆ in Aarhus, Denmark, is built in part from reused construction waste. Designed by Lendager Architects for Kilden & Hindby and PFA Ejendomme, in collaboration with MOE Consulting Engineers and Kaj Ove Madsen, Aarhus Municipality and Realdania, it is due to be completed 2024. Reuse and recycling innovations in the facade include the use of decommissioned composite wind turbine blades for solar shielding, aluminium roof plates for the facade, wooden cassettes, wood insulation, low-carbon concrete and insulation from waste textiles. The reused aluminium facade comes from two different renovation projects, where they had been discarded, plus water-damaged panels from a supplier. Standing 78 m high, the structure is steel, concrete and timber. All materials have been thoroughly tested so that they continue to meet the requirements and regulations.

Extruded aluminium lighting, Original Coffee, Copenhagen.

Cross-section through the Kvadrat Acoustics Soft Cells Broadline panels. The framed wall mounted units are constructed from extruded recycled aluminium, a recycled polyethylene terephthalate (rPET), polyester, cover, and recycled glass wool absorbent. Using extrusions means the dimensions of the product can be tailored to the application. The fabric is held onto the frame by a mechanical locking feature.

Statoil regional headquarters, Fornebu, Norway, completed 2012, designed by A-lab, features a steel and concrete superstructure, powder coated aluminium skinned composite panels (Etalbond made with 3105 sheet) with integrated insulation, triple-glazed windows and external sun protection

Extruded, brushed and bright blue anodised aluminium cover

Sandwich panels consisting of a foamed polyethylene terephthalate (PET), polyester, core. The skins shown here are glass fibre reinforced epoxy and aluminium sheet.

Modified atmosphere packaging (MAP), made up of polypropylene (PP), aluminium metallised polyethylene terephthalate (PET), polyester, and an inner layer of weldable polyethylene (PE). While this multilayer structure offers excellent protection of food products, improving shelf life, it is impossible to separate and recycle the individual materials.

Multilayer film vacuum packaging, made up of aluminium metallised polyethylene terephthalate (PET), polyester, and an inner layer of weldable polyethylene (PE). While this multilayer structure offers excellent protection against oxidisation and moisture, it is impossible to separate and recycle the individual materials.

Haig Club promotional packaging, in biaxially-oriented polyethylene terephthalate (BOPET), polyester, metallised and printed, manufactured by Progress Packaging. Image Progress Packaging.

Lightweight sandwich panel, constructed from honeycomb aluminium core held between cast polymethyl methacrylate (PMMA), acrylic, sheets. Typically, aluminium alloy 3003 or 5052 are used for the core.

Lightweight sandwich panel, constructed from honeycomb aluminium core held between cast polymethyl methacrylate (PMMA), acrylic, sheets. Typically, aluminium alloy 3003 or 5052 are used for the core.

Mobile phone cover made from injection moulded translucent polycarbonate (PC) with vacuum metallised aluminium backside for added depth effect

Miss K table lamp, by Philippe Starck for Flos, 2003, featuring an injection moulded transparent polycarbonate (PC) diffuser, metallised with aluminium to create a reflective finish that is thin enough to become see-through when backlit

Trælasthuset (The Timber House) is a parking garage in Nordhavn, Copenhagen, by Vilhelm Lauritzen Arkitekter, completed 2002. The cladding consists of laminated glass, recycled aluminium and Thermwood pine.

Cross-car beam produced by Elring Klinger with thixomoulded magnesium alloy assembled onto hydroformed aluminium alloy, over-moulded with 60% glass fibre reinforced polyamide (PA-GF60), nylon. This type of hybrid metal construction provides maximum strength to weight, whilst allowing design freedom for the integration of instrument panel, steering, airbags, hot and cold air, and all other necessary elements.

Spidsen af ​​Nordø (Tip of Nordø, Redmole Spidsen), Denmark, by Cobe Architects, Vilhelm Lauritzen Architects and Tredje Natur, completed 2023. The facade concept for the cylindrical structure was designed with the aim of creating good daylight conditions throughout the building. To reduce glare, facade elements are narrower towards the west, south and east of the building, where the facade is the most exposed to daylight. Towards the west, north and east, the facade gradually opens up, letting in more light. Thus, the six individually angled facade elements vary in size and glazing ratios based on hour-by-hour weather simulations. The prefabricated solar control glass units in anodised aluminium were manufactured and installed by Feldhaus Fenster + Fassaden.

Spidsen af ​​Nordø (Tip of Nordø, Redmole Spidsen), Denmark, by Cobe Architects, Vilhelm Lauritzen Architects and Tredje Natur, completed 2023. The facade concept for the cylindrical structure was designed with the aim of creating good daylight conditions throughout the building. To reduce glare, facade elements are narrower towards the west, south and east of the building, where the facade is the most exposed to daylight. Towards the west, north and east, the facade gradually opens up, letting in more light. Thus, the six individually angled facade elements vary in size and glazing ratios based on hour-by-hour weather simulations. The prefabricated solar control glass units in anodised aluminium were manufactured and installed by Feldhaus Fenster + Fassaden.

Akonite longboard features BComp AmpliTex flax fibre and carbon fibre laminated with epoxy, with a core of ash and balsa wood. Trucks are typically cast aluminium alloy A356 and the wheels polyurethane resin (PUR).

Structural sandwich panels with with aluminium honeycomb core. Typically, aluminium alloy 3003 or 5052 are used. Glass fibre reinforced epoxy skins provide excellent stiffness- and strength-to-weight. Aluminium faced honeycomb panels are relatively heavier, but offer excellent mechanical properties combined with a durable and decorative surface. Aluminium alloy 1050 is one of the most common sheet materials used where no special mechanical or chemical properties are required.

The Colnago C60 is flagship road race frame, handmade in Italy. Using high performance Toray T1000 carbon fibre combined with epoxy, the tubes are bladder moulded and assembled onto the bottom bracket. The frame is clear lacquered to reveal the carbon fibre weave below. To keep weight to a minimum, the chainring is forged and machined from aluminium alloy 7075. Image Colnago.

Stella McCartney metallised laminate packaging utilising a 3-ply Tipa compostable plastic film. Tipa packaging films are based on a mix of bio-based and petroleum based compostable plastic. The quantity of bio-based ingredients ranges from 20-80% depending on the requirements of the application. This product may be composted in industrial facilities. Image Tipa.

Stella McCartney zipper pouch packaging utilising Tipa compostable plastic. Tipa packaging films are based on a mix of bio-based and petroleum based compostable plastic. The quantity of bio-based ingredients ranges from 20-80% depending on the requirements of the application. This product may be composted in industrial facilities. Image Tipa.

Colour-tinted and frosted glass cover on the backside of the Apple iPhone 15, with aluminium alloy bezel. The glass is coloured throughout, to create a translucent effect and coated on the backside to mask the internals. The aluminium bezel is machined and injection over-moulded.

Beosound Balance, by Benjamin Hubert for Bang & Olufsen, 2022, with wool-blend knitted fabric speaker cover and anodised aluminium top

Grip Table, 2011, designed by Troels Grum-Schwensen, features a high pressure laminate (HPL) paper top, supported by an extruded aluminium beam with cast aluminium legs, polyester powder coated

Bellevie bench end piece (arm and back rest), by Pagnon & Pelhaître for Fermob, in welded and powder coated aluminium.

Boa table, by Stefan Diez for Hay, 2023, featuring extruded aluminium legs produced from Hydro Circal 75R.

Turbo pendant light, by Louis Weisdorf for Gubi, 1965, formed in powder coated aluminium

Entr’acte screen printed CD packaging made with vacuum sealed aluminised plastic film. The outer layer is polyethylene terephthalate (PET), polyester, and the inner layer is polyethylene (PE), to allow for heat sealing. The thin layer of aluminium is sandwiched between.

Makita impact driver, with twin-shot injection moulded glass fibre reinforced polycarbonate (PC-GF) body and thermoplastic elastomer (TPE) grip. The gearbox housing is die cast in aluminium A383 (ADC12).

Bang & Olufsen BEOPLAY HX headphones feature lambskin leather ear cushions, with polyurethane foam padding and a gold-colour anodised aluminium frame, using the dip and dye method.

Nordland vapour permeable, UV-durable underlay for use in roof and wall constructions. The upper spunbonded polypropylene (PP) is adhesive-laminated onto a perforated aluminium foil (this prevents harmful UV light penetrating the fabric and breaking down the plastic), a microporous PP film, reinforcing grid and lower spunbonded PP.

Discover lighting system, designed by Ernesto Gismondi for Artemide, 2015, features an etched acrylic diffuser housed in an aluminium profile. The light interacts with the micro-incisions on the surface of the acrylic, creating an edge glow (or lit edge) effect.

Fluorescent-dyed polymethyl methacrylate (PMMA), acrylic, over aluminium foam. The laser cut edge of the acrylic appears brighter than the faces, due to a phenomenon known as edge glow, or lit edge. It is caused by lightwaves being refracted internally and transmitted out through the edge, rather than the surface. The effect is enhanced by fluorescent pigment.

Cross-car beam produced by Elring Klinger using hydroformed aluminium alloy, over-moulded with 60% glass fibre reinforced polyamide (PA-GF60), nylon. This type of hybrid metal construction provides maximum strength to weight, whilst allowing design freedom for the integration of instrument panel, steering, airbags, hot and cold air, and all other necessary elements.

Metallised paper, such as used for wrapping chocolate, is produced with a thin layer of aluminium on the surface of lightweight paper. The aluminium provides functional barrier properties, as well as a bright metallic backdrop for printing. The aluminium layer is so thin that it is considered recyclable along with regular paper.

Aluminium cladding and oak lined interior on Køge Nord Station footbridge, by architects Cobe and Dissing+Weitling, 2020.

Plate by David Thulstrup for ReformCPH, is a kitchen counter made with hand brushed aluminium and MDF. The surface of the aluminium is lacquered to protect it from marks and stains. The countertop is stainless steel.

Cityring Østerport Station, Copenhagen, features an origami ceiling made up of faceted panels of powder coated aluminium cladding around the skylights, bringing light from the outside in, and cast reinforced concrete structure.

Trax airport seating, by Rodney Kinsman for OMK, 1989, features a self-skinning polyurethane resin (PUR) foam upholstery, cast and powder coated aluminium arms and an extruded aluminium beam

Boeing 737 800, which utilises aluminium alloy 2024 in the fuselage skin, slats and flaps, 7075 in the frames, stringers and ribs, 7178 in the wing upper skin, spars and beams, 7055 in the wing lower skin. Aircraft are typically coated with an abrasion resistant polyurethane resin (PUR) paint.

The Eye Film Museum, Amsterdam, by Delugan Meissl Associated Architects (DMAA), completed April 2012. The outside is clad in Alpolic flame retardant aluminium composite material (ACM). It is a laminated panel, consisting of two 0.5 mm aluminium alloy skins (3105-H14, 3005-H14 or 5005A), anodised and coated (the FR panel is coated with Lumiflontm, a flame retardant fluoropolymer, FEVE), with a mineral filled polyethylene (PE) core. ACM can be flat, or formed, and precisely cut to a profile. It is used in large public buildings, including airports, museums, offices and other demanding high rise projects.

Lotus Elise S1 Chassis, launched 1995, manufactured by Hydro Aluminium from extruded 6063 and bent sheet 3105 aluminium alloy, riveted and bonded with 3M epoxy adhesive. The two-part adhesive is post-cured for enhanced strength. The bare chassis weighs just 68 kg.

The metal chassis for the Jaguar XE, launched 2014, is made up of 75% aluminium and 25% steel for an exceptionally light and strong monocoque. It utilises riveted and bonded Novelis RC 5754, a strain hardening AlMgMn aluminium alloy. Developed especially for automotive bodies, it is soft and formable, making it economic for production. It is available with a high level of recycled content, using scrap from manufacture. Lightweight aluminium chassis utilise a range of other alloys, depending on the requirements of the parts, including 3000 series, 5000 series, 6000 series and 7000 series for the stiffest parts. Image Jaguar.

Lightweight aluminium chassis utilise a range of alloys in the stamped metal parts. They tend to be riveted and bonded, because this allows greater design freedom on the joint geometries. 5000 series alloys (AlMg), such as 5005, 5251, 5083 and 5754, have excellent forming characteristics, which allows for more curves and deeper profiles compared to traditional steel chassis. Another advantage of this group of alloys is that they are highly resistant to salt water and corrosive environments.

Danzka Vodka bottle, produced by impact extrusion, are made with aluminium alloy. It is coated to protect the surface from oxidising and tarnishing. Typical alloys used in these products include 3003, 5005 and 5083; similar to aluminium cans.

Marriott hotels, Paris Charles-de-Gaulle airport, by Manuelle Gautrand Architecture, completed 2022, features a colour powder coated and gloss lacquered aluminium alloy facade.

CopenHill, also known as Amager Bakke, is a waste-to-energy plant in Copenhagen designed by BIG, completed 2019. The 1.2-metre-tall and 3.3-metre-wide aluminium boxes that are stacked like gigantic bricks are produced by Speira using Tectura Giant 5083 aluminium alloy. Image Hydro.

Aesop aluminium squeeze tube packaging, produced by impact extrusion. The surface is printed and lacquered for protection. Aluminium provides a very effective barrier to light and oxygen, ensuring a long shelf life. As a collapsible tube, it reduces the risk of contamination of the contents.

HTC Legend mobile phone housing, sculpted from a single piece of extruded aluminium. The profile is extruded sideways and then CNC machined to the final shape. Techniques have evolved to mass produce fully machined housings like this (same as Apple unibody products). All the scrap can be recycled directly.

Aluminium open cell foam, with large pores.

Bright anodised aluminium colour and finish samples, using the dip and dye method

Bright anodised aluminium colour and finish samples, using the dip and dye method

Lightweight and high-strength aluminium aircraft wing skin

Dock mooring cleat, in die cast aluminium 535 (almag 35), an aluminium-magnesium alloy with very good resistance to corrosion, in particular salt water marine environments

Shanghai Poly Grand Theatre, by Tadao Ando, completed 2014, features extruded aluminium interior walls painted to look like wood

Extruded 6061 aluminium solar panel structure, reinforced with single wall carbon nanotubes (SWCNT) for enhanced strength (250 MPa) and stiffness (140 GPa) compared to 6061 T5

Titania light, by Alberto Meda and Paolo Rizzatto for Luceplan, 1989, produced from laser cut sheets of anodised aluminium. The colour comes from filters over the light source

Continuel-mobil Argent, by Julio le Parc, 1967, is made with squares of bright anodised aluminium, held on nylon threads

Mobile phone covers, made with stamped aluminium sheet and painted with a gradient colour effect

Mobile phone covers, made with stamped aluminium sheet, painted matte and featuring a diamond cut camera bezel

Mobile phone covers, made with stamped aluminium sheet, painted matte and featuring a diamond cut camera bezel

Installation in Luxembourg made with lightweight, semi-rigid aluminium ducting

Bright anodised aluminium colour and finish samples, using the dip and dye method

Pressed aluminium camera fascia, gradient colour anodised

Beijing Airport Terminal 3, designed by Foster and Partners and engineered by Arup, completed 2008, features louvres manufactured from extruded aluminium, mounted to a trussed steel roof structure

Ghost, by Kader Attia, 2007, is a large installation of a group of Muslim women in prayer, made with aluminium foil

Aluminium bezel for a consumer electronic product, showing the stages of forging (top) a near net shape, followed by CNC machining (bottom) precise features

Dalian International Conference Center, China, by Coop Himmelb(l)au, completed 2012, features Novelis coil-anodised aluminium cladding, which provides enhanced protection from the marine environment

Aluminium cladding on Køge Nord Station footbridge, by architects Cobe and Dissing+Weitling, 2020

Slipstream sculpture, Heathrow Airport, UK, by Richard Wilson, 2014, features a polished aluminium skin over a steel structure, held together by half a million rivets

Nuage vase, by Ronan & Erwan Bouroullec for Vitra, 2016, in extruded and anodised aluminium, using the dip and dye method

PH 5 light, by Poul Henningsen for Louis Poulsen, 1958, features a pressed aluminium diffuser, painted matte white to produce a uniform light, and frosted glass

PH Snowball light, by Poul Henningsen for Louis Poulsen, 1958, features a pressed aluminium diffuser with matte painted undersurfaces and glossy top surfaces to reflect the diffused light

Semi pendant light, by Claus Bonderup and Torsten Thorup for Gubi, 1968, is spun from aluminium sheet and painted

Lightweight aluminium open cell foam

Aluminium car body stampings

Aluminium roll formed profiles for automotive and architecture. 3000 series is the most popular aluminium for this type of production

High aspect ratio, hollow extruded aluminium profile

Hot hydroformed aluminium

Beijing Airport Terminal 3, designed by Foster and Partners and engineered by Arup, completed 2008, features louvres manufactured from extruded aluminium, mounted to a trussed steel roof structure

Architectural corrugated aluminium, press-formed

Hall du Deich, Ettelbrück, Luxembourg, by Besch da Costa Architectes, completed 2011, clad in Kalzip gold colour coated extruded aluminium 3004

Apple iPod Shuffle 2nd generation, machined aluminium unibody, colour anodised

Hydroformed sheet aluminium

Statoil regional headquarters, Fornebu, Norway, completed 2012, designed by A-lab, features a steel and concrete superstructure, powder coated aluminium skinned composite panels (Etalbond made with 3105 sheet) with integrated insulation, triple-glazed windows and external sun protection

Selfridges store in Birmingham, UK, opened 2003, features 15,000 aluminium discs mounted onto sprayed concrete facade. Designed by Future Systems and Engineered by Arup.

Bang & Olufsen Beosound A1 features a perforated and pressed aluminium sheet that has been finished and anodised.