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

The F-22 Raptor, a stealth fighter aircraft from Lockheed Martin, first flown in 1997. Titanium alloy (principally grade 5, Ti 6-4) makes up around one-third of the aircraft. Hot isostatic pressing was utilised on large cast parts, such as the canopy deck and wing side-of-body, to minimise porosity and so enhance strength to weight and reliability. Around 350 parts, one-quarter of the aircraft by weight, is made up of resin transfer moulded (RTM) carbon fibre reinforced epoxy composite. High performance carbon fibres are used, such as T700 for lower cost parts, T800 for higher strength parts and T1000 for ultrahigh strength applications. Examples include the fuselage frame, doors, wing spars and honeycomb sandwich panels. Advanced RTM resin systems for these type of applications include epoxy and bismaleimide. The canopy consists of two sheets of polycarbonate (PC), sandwiched between two layers of glass, fusion bonded in an autoclave and drape formed. Indium-tin-oxide is vacuum deposited onto the canopy to reflect radar waves (scatters radio waves in various directions so as not to be detected by radar), which gives it a golden colour tint. Image Lockheed Martin Aeronautics.

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.

Ceramic outdoor table by Muller Van Severen for Hay, features a bright yellow porcelain top on a powder coated steel tube and concrete base.

Swing light, by House Doctor, in brass plated iron.

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

Vita Student Newcastle, UK, clad in sandstone and elZinc rhomboid shingles (manufactured by Asturiana de Laminados). Image SIG Zinc and Copper.

The Stade de Soccer de Montreal was designed as a collaboration between Canadian studios Saucier + Perrotte and HCMA. It is clad in elZinc plate (slate finish) manufactured by Asturiana de Laminados. Image SIG Zinc and Copper.

Rhomboidal zinc shingle cladding. Image SIG Zinc and Copper.

Die casting in Zamak 5, this complex casting is a central support unit for a large complex medical imaging unit. Image International Zinc Association.

Die casting in Zamak 5 by Matthies Druckguss (Germany). The three-piece bayonet XT-A is a heat sink for an LED light. Image Matthies Druckguss (Germany).

Die casting in Zamak 5 by Adolf Föhl Germany. It is a shift lever that connects the shifter and the gear in ZF automotive gearboxes. Image Adolf Föhl Germany.

Lime Wharf in Hackney, London, completed 2014, designed by Stephen Davy Peter Smith Architects, featuring standing seam zinc cladding

Fritz Hansen PK22 chair, by Poul Kjærholm, 1956, features brushed stainless steel structure and natural wicker seat

The Lotus x Hope HB.T 2020 Team GB Tokyo Olympic carbon fibre composite track bike. A range of carbon fibres are used, from standard to ultra high modulus, depending on the requirements of each specific part of the frame and assembly. Epoxy provides the strongest matrix. The headset and handlebars, as well as other components, are 3D printed titanium (Ti-6Al-4V). In collaboration with Lotus Engineering, Renishaw 3D printed the parts throughout the development process using aluminium alloy (AlSi10Mg), enabling the quick turnaround of design changes. Using carbon fibre for these parts is significantly slower and more restricted, because new moulds are required each time a change is made. With 3D printing, the components can be outputted directly from the updated CAD file.

The Aurora frame by No. 22 Bicycle Company is produced with high performance titanium alloy (grade 9, Ti 3-2.5). The colour of the frame is applied as part of the protective anodising process to ensure a long lasting and high quality finish. Image No. 22 Bicycle Company.

Lindberg Air Titanium glasses, created together with architectural firm Dissing+Weitling. These are the first rimless spectacles made of titanium alloy. They make use of a unique spiral hinge, which removes the need for screws, rivets and other unnecessary elements. Image Lindberg.

Anodised titanium with surface treatment to increase grain size

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

Anti-slip stair nose on the London Underground by AATI, in cast nickel bronze with embedded silicon carbide (SiC) particles for added grip and durability.

Stainless steel watch strap, made with 316L and vacuum deposition coated to produce a bright gold and hardwearing finish.

Lavabo stainless steel sink, vacuum coated with a brass-coloured finish, to produce an extremely durable surface with a stable colour.

Mobile phone cover, featuring steel with two layers of colour produced by physical vapour deposition (PVD), which is laser etched to produce a graphic visual effect. Aluminium titanium nitride (AlTiN) provides the black, masking a layer of silver chromium nitride (CrN) below.

Gucci watch back plate, in stainless steel, chemical etched graphics, with titanium carbonitride (TiCN) coating for protection and to provide a very durable rose gold colour

Fuel cell bipolar plates, stamped in stainless steel. The sheet is pre-coated with physical vapour deposition (PVD) titanium nitride (TiN)

Mobile phone cover, featuring steel with two layers of colour produced by physical vapour deposition (PVD), which is laser etched to produce a graphic visual effect. A top layer of zirconium carbonitride (ZrCN) provides the blue colour, and is selectively removed to reveal the gold coloured zirconium nitride (ZrN) layer below.

iPhone 4 bezel, forged from stainless steel, CNC machined and over-moulded with glass fibre reinforced nylon (PA-GF)

iPhone 4 bezel, forged from stainless steel, CNC machined, laser welded and over-moulded with glass fibre reinforced nylon (PA-GF)

Stainless steel brake discs on the Rein4ced Hardtail cross country mountain bike.

Stainless steel wire mesh, type 304, used for architectural cladding, facades and fences, as well as interior room dividers and covers.

Deep drawn stainless steel mixing bowls by WMF.

Knitted stainless steel 304 fabric for upholstery, interiors and apparel by Inntex, embossed with a floral motif. Photo courtesy of Inntex.

ReformCPH kitchen countertop, with seamless welded sink, in 304 stainless steel.

Arcs mirror by Muller Van Severen for Hay, 2023, in mirror polished stainless steel.

Chemically coloured and quilted stainless steel sheet, used in architectural cladding, interiors, signage, catering, luggage and furniture. Chemical colouring produces intense colours (interference) on the surface of stainless steel by enhancing the naturally occurring layer of chromium oxide.

Chemically coloured and embossed stainless steel sheet, used in architectural cladding, interiors, signage, catering, luggage and furniture. Chemical colouring produces intense colours (interference) on the surface of stainless steel by enhancing the naturally occurring layer of chromium oxide.

Polished, chemically coloured and selectively etched stainless steel sheet, used in architectural cladding, interiors, signage, catering, luggage and furniture. Chemical colouring produces intense colours (interference) on the surface of stainless steel by enhancing the naturally occurring layer of chromium oxide.

Embossed, chemically coloured and selectively etched (pattern) stainless steel sheet, used in architectural cladding, interiors, signage, catering, luggage and furniture. Chemical colouring produces intense colours (interference) on the surface of stainless steel by enhancing the naturally occurring layer of chromium oxide.

Embossed stainless steel sheet, used in architectural cladding, interiors, signage, catering, luggage and furniture.

Mandrel bending stainless steel tube.

Puma bike, by Vexed Generation and manufactured by Biomega, 2004, with a type 410 martensitic stainless steel brake disk

Chemically coloured stainless steel, used on building facades and signage. The result of an electrochemical process, the colour is structural and so can flip depending on the thickness and angle of view. It is resistant to corrosion, enhancing the natural durability of stainless steel, and the range of colours includes red, green, blue, gold, bronze and black.

iPhone 4 bezel, forged from stainless steel, prior to CNC machining. Forging produces the strongest possible bezel, because the grain of the steel is optimised and the structure hardened.

Vertu mobile phone cover, machined from stainless steel and welded

Stainless steel jewellery formed by metal injection moulding (MIM)

Stainless steel formed by metal injection moulding (MIM)

Parmigiano Reggiano cheese mould in perforated stainless steel

Georg Jensen Panton dish in bright polished stainless steel

Unfinished camera body in hydroformed steel

Stages in the hydroforming process, using stainless steel tube

Honeycomb structured thin sheet stainless steel

Your spiral view, Olafur Eliasson, 2002, is fabricated from folded stainless steel

3M Elipar S10 LED curing light features a hydroformed stainless steel body, produced from a seamless welded tube.


nh light, designed by Neri & Hu for Artemide, features a blown glass diffuser and brass hanging hook

Silver coated nonwoven embossed polyamide (PA), nylon. The thin metal layer is applied by chemical vapour deposition (CVD). These materials are used for shielding applications in products and interiors.

Nelson Bubble Lamp, by George Nelson for Herman Miller, 1952, formed by spraying a polyvinyl chloride (PVC) mixed with a webbing agent (which causes the PVC to form filaments) onto a steel wire frame, and finished with a layer of pure PVC spray coating

Centre Pompidou, France, by Richard Rogers and Renzo Piano, completed in 1977, featuring a tubular steel exoskeleton, cast low alloy steel ‘gerberettes’ (visible 11 ton structure joining the floor trusses to the end columns) and curved polymethyl methacrylate (PMMA), acrylic, glazed walkways.

Kirinite is a cast polymethyl methacrylate (PMMA), acrylic, which comes in a wide range of swirling colours and effects.

Kirinite is a cast polymethyl methacrylate (PMMA), acrylic, which comes in a wide range of swirling colours and effects. Here it has been machined as a trumpet mouthpiece. It is also commonly used for knife handles and pen bodies.

Antenna technology demonstrator, manufactured from injection moulded polycarbonate, which has been laser direct structured (LDS) to allow for localised metal plating

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.

Kitchen made with Dinesen Layers in oak, an engineered wood three-layer construction of solid timber for enhanced stability. The glass ceramic induction cooktop is set flush in a stainless steel kitchen counter.

Metal emblems and logos are made by electroforming nickel, printing, embossing, chemical etching and die cutting

Metal emblems and logos are made by electroforming nickel, printing, embossing, chemical etching and die cutting

RB211-524 gas turbine jet engine by Rolls-Royce, 1995-96, featuring single crystal turbine blades cast from nickel Inconel 718 superalloy

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.

Panasonic Toughbook cover, thixomoulded (similar to injection moulding) in magnesium AZ91. The same technique is used in the production of cameras, mobile phones, displays and televisions. The magnesium is painted to protect it from oxidisation when in use.

Forged Elektron AZ80 magnesium alloy racing wheel, which is significantly lighter than aluminium (6 kg per wheel). Magnesium wheels are either gravity die cast or forged. Forged wheels have superior mechanical properties and the wall sections may be thinner than with casting, resulting in lighter wheels. The drawback of magnesium generally is the relatively poor corrosion resistance and resilience, so they tend to be only suitable for short term use, such as racing wheels. Image by Luxfer.

Copenhagen Opera House, by Henning Larsen, completed 2004, features a stainless steel (1.4435) and laminated glass facade by Waagner Biro, beige Jura Gelb limestone cladding and one of the largest canopy roof structures in the world. The 90 x 158 m roof is based on a low alloy steel box construction covered with 14,000 m2 of standing seam, stainless steel roof panels. The substructure for the 9,000 m2. roof soffit (underside) is a cold formed thin gauge steel structure covered with mat-coated Alucobond composite panels, designed and produced by Grønbech Construction.

Copenhagen Opera House, by Henning Larsen, completed 2004, features a stainless steel (1.4435) and laminated glass facade by Waagner Biro, beige Jura Gelb limestone cladding and one of the largest canopy roof structures in the world. The 90 x 158 m roof is based on a low alloy steel box construction covered with 14,000 m2 of standing seam, stainless steel roof panels. The substructure for the 9,000 m2. roof soffit (underside) is a cold formed thin gauge steel structure covered with mat-coated Alucobond composite panels, designed and produced by Grønbech Construction.

Copenhagen Opera House, by Henning Larsen, completed 2004, features a stainless steel (1.4435) and laminated glass facade by Waagner Biro, beige Jura Gelb limestone cladding and one of the largest canopy roof structures in the world. The 90 x 158 m roof is based on a low alloy steel box construction covered with 14,000 m2 of standing seam, stainless steel roof panels. The substructure for the 9,000 m2. roof soffit (underside) is a cold formed thin gauge steel structure covered with mat-coated Alucobond composite panels, designed and produced by Grønbech Construction.

Plaster ceiling mouldings and wrought iron railings, Gallery of Modern Art (GoMA), Glasgow, Scotland. The characteristic flowing shape of wrought iron work is the result of its combination of malleability with relatively high strength and stiffness. Together, this enables to construction of elegant and ornate details.

Paddington station, London, UK, by Isambard Kingdom Brunel, completed 1854, features wrought and cast iron. Iron played a significant role in the development of architecture, because it enabled longer spans and thinner sections, creating light and space in public buildings that was not possible before. In Paddington, the glass panes have been replaced with polycarbonate (PC), for safety.

Compacted graphite iron (CGI) casting by BAS Castings, UK. Almost twice the strength of grey cast iron, it can be cast near net-shape, which helps to maintain relatively low manufacturing costs. Its good fatigue properties, ease of machining, thermal and damping properties are the reason it is gaining popularity in automotive engine applications such as engine blocks, flywheels, clutch components and piston rings. Image BAS Castings.

Austempered ductile cast iron casting by BAS Castings, UK. Austempered ductile iron (ADI) is a development on ductile cast iron that enhances mechanical properties whilst maintaining ductility and casting quality. Additions of copper, nickel and molybdenum are made to improve hardenability through heat treatment. Strengths of up to 1,400 MPa are feasible. Image BAS Castings.

Ductile cast iron casting by BAS Castings, UK. It has a lower melting temperature than steel, and so cheaper to cast, especially into large and complex parts. Image BAS Castings.

Ductile cast iron casting by BAS Castings, UK. It has a lower melting temperature than steel, and so cheaper to cast, especially into large and complex parts. Image BAS Castings.

Cast iron freestanding bath foot.

Screen print with gold leaf.
Relevant materials
Gold, Au, 24 ct, Pure gold

Astronaut Scott Parazynski during a spacewalk on STS-120. The ultra-thin gold coating on the visor provides protection from harmful solar radiation. Image NASA.
Relevant materials
Gold, Au, 24 ct, Pure gold

While silver is the most common finish for a brass instrument mouthpiece, gold provides a tarnish-free surface that will hold its shine for longer. Maintaining a super smooth finish means the mouthpiece feels less 'grippy' and so can help with lip flexibility and control.
Relevant materials
Gold, Au, 24 ct, Pure gold

Gold has incredible malleability, which allows it to be beaten into very thin sheets (gold leaf). The foils are used for decoration and gilding on artwork, engraving, frames, packaging and food (gold is inert and edible). It is said than an ounce of gold can be beaten into gold leaf covering 9 m2.
Relevant materials
Gold, Au, 24 ct, Pure gold

Goldwork on fabric. Twisted gold wire is couched onto the surface of the fabric by hand to create a 3D pattern.
Relevant materials
Gold, Au, 24 ct, Pure gold

Musee D’Art Moderne Grand Duc Jean (Mudam), Luxembourg, designed by Leoh Ming Pei, completed 2006, features a glass roof supported by an intricate stainless-steel tension system.

The roof of the British Museum Queen Elizabeth II Great Court, London, by Foster & Partners, completed 2000. The largest covered public square in Europe, the roof consists of 3,312 individual panels of glass - no two panels are the same - held within a triangulated steel lattice shell that acts both as primary supporting structure and framing for the glass. The toughened and laminated glass panes are screen printed with a dot matrix pattern (frit) to reduce solar gain.

Steel House Copenhagen, the former head office of Dansk Metals, Denmark, features a Cor-Ten steel facade

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).

Copper lined cheese vat, to ensure the highest possible thermal conductivity combined with hygiene. The use of copper vats is compulsory for many traditional cheeses

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.

Diatech diamond blade. Image by Diatech.

Adnet coffee table, by Jacques Adnet for Gubi, 1950, featuring stitched pigmented leather trim, gilded brass and glass top.

IC light, by Michael Anastassiades for Flos, 2014, features a blown opal glass diffuser and brass frame

Knitted copper wire fabric for upholstery, interiors and apparel by Inntex, embossed with a floral motif and coated with polyurethane resin (PUR) to maintain the bright copper colour. Image by Inntex.

Copper flakes cast into water-clear polymethyl methacrylate (PMMA), acrylic, sheet.

Copper coating on lightweight nonwoven polyamide (PA), nylon. The thin metal layer is applied by chemical vapour deposition (CVD). These materials are used for shielding applications in products and interiors.

Copper coated nonwoven embossed polyamide (PA), nylon. The thin metal layer is applied by chemical vapour deposition (CVD). These materials are used for shielding applications in products and interiors.

Copper coated polyamide (PA), nylon. The thin metal layer is applied by chemical vapour deposition (CVD). These materials are used for shielding applications in products and interiors.

A yellow brass kitchen counter top on dark stained oak cabinets. The uncoated brass develops a rich patina over time, revealing patterns of use.

Handmade trumpet, made with different types and colours of copper alloy, including brass (the colours are the result of different proportions of zinc) and nickel silver. The proportion of alloy affects the sound, with high proportions of zinc producing brighter tones, and less zinc (more copper) producing warmer tones.

Nordea Christianshavn, Copenhagen, by Henning Larsen, completed 2000, features a copper facade that will slowly turn green over time as the copper develops its characteristic verdigris patina.

Victor Hugo by Auguste Rodin, 1883, cast in bronze.

The Axel Towers, Copenhagen, by Lundgaard & Tranberg Arkitekter, completed 2017, features a brass cladding made up of 20% zinc.

Equestrian statue of Francisco Pizarro, Trujillo, Spain. Lost wax cast in bronze, the surface have evolved a variegated green patina (verdigris) over many years. This layer develops naturally on the surface and protects the substrate beneath from further corrosion.

NEMO (National Center for Science and Technology), Amsterdam, by Renzo Piano, completed 1997. It is clad in green patinated copper. The process of patination is very slow, taking many years to become green and only if the conditions are right. So, the copper is pre-patinated using a chemical process to give the hardwearing and weather resistant layer on the surface a head start prior to installation.


Copper with a small amount of tin (Sn, 3.5-4.5%) produces a rich copper-red colour cladding. A brown-red surface oxidation is typical for this alloy, with darker undertones. The material then gradually changes to dark brown - the patina forms more slowly than with pure copper.

Beat lamp, by Tom Dixon, is made from brass. Handmade by craftsmen of Moradabad (Uttar Pradesh district, India), the shade is spun into shape, and the interior is hammered to strengthens the material, hide defects and create a surface pattern. In this example the outside is patinated black and the inside lacquered

PH Artichoke light, by Poul Henningsen for Louis Poulsen, 1958, features a diffuser made from 72 laser cut and brushed copper "leaves", coated and lacquered.


Experimentarium, Copenhagen, Denmark, designed by CEBRA, features a helix staircase clad in 10 tons of copper alloy

The Faroe-Falster cable-stayed bridge, Denmark, completed 1984, designed by Erik Villefrance, features a steel box girder superstructure with piers and pylons in reinforced concrete, and high-tensile steel wire cable

The Faroe-Falster cable-stayed bridge, Denmark, completed 1984, designed by Erik Villefrance, features a steel box girder superstructure with piers and pylons in reinforced concrete, and high-tensile steel wire cable.

The road suspension section of the Storebæltsbroen (the Great Belt bridge), Denmark, by Dissing+Weitling, completed 1998, is one of the largest examples of this type of bridge in the world. The pylons are 254 m tall and were cast on-site, 4 m at a time using climbing formwork (jumpform). All except the foundations, which were prefabricated and then brought on site. The suspended road, 2.7 km long between concrete anchor blocks, is made up of steel sections, held with high tensile cables.


Building site, Langfang, China, with steel rebar being prepared for the concrete pillars that will support the floor slabs. The steel structure behind is supporting the formwork for the reinforced concrete floor slab

Fringe light, by Hans-Agne Jakobsson for Warm Nordic, 1960, features a brass-plated steel and viscose cord shade

Palissade outdoor furniture, by Ronan & Erwan Bouroullec for Hay, in galvanised and powder coated steel.

Hee chair, by Hee Welling for Hay, is produced from welded steel, which is galvanised (zinc) and powder coated with colour.


Satellite, by Mathieu Matégot for Gubi, 1953, features a perforated and powder coated steel shade

Tropique dining table, by Mathieu Matégot for Gubi, 1950, features a perforated, pressed, folded, welded and powder coated steel top

Interior walls in Terminal 3, Copenhagen Airport, Denmark, built 2020, designed by Vilhelm Lauritzen Architects, made from perforated steel panels and polyester powder coated

Rapha performance eyewear packaging, manufactured by Progress Packaging. Polyester powder coated pressed steel tin enclosed in litho printed and raise-embossed card slip case. Image Progress Packaging.

Nelson Bubble Lamp, by George Nelson for Herman Miller, 1952, formed by spraying a polyvinyl chloride (PVC) mixed with a webbing agent (which causes the PVC to form filaments) onto a steel wire frame, and finished with a layer of pure PVC spray coating

The Fehmarn Sound Bridge, Germany, completed 1963, features steel arches, from which the central span is suspended by cables, braced with steel beams.

Hay Palissade Dining Bench by Ronan & Erwan Bouroullec, in galvanised steel.

The Silo in Copenhagen, by Cobe, completed 2017, features a galvanised steel facade hung on the original reinforced concrete structure of the industrial grain silo, mounted on large steel brackets. The prefabricated batch galvanised steel units, manufactured by Skandinaviska Glassystem, act as a climate shield and provide a dramatic appearance reflecting the surrounding light while forming the distinctive zinc patina. A steel with a specified minimum silicon content to achieve at least 100 microns of galvanised coating was used for the 3 mm thick facade plates. It was batch galvanised, as opposed to using pre-galvanised sheet, to avoid exposed steel edges after cutting which would corrode. It is estimated the galvanised steel will last 50 years and can be dismantled and re-galvanised to extend its life.

Zinc galvanised mild steel ring rolled and press formed gutter profile.

Electricity pylons are constructed from carbon steel sections welded to form a truss structure. They are galvanised and painted to protect them from corrosion.

Electricity pylons are constructed from carbon steel sections welded to form a truss structure. They are galvanised and painted to protect them from corrosion.

Electricity pylons are constructed from carbon steel sections welded to form a truss structure. They are galvanised and painted to protect them from corrosion.

Kunsthal 44Møen, Denmark, clad in sheets of hot-dip galvanised (zinc) mild steel, cold-rolled to produce a linear corrugated pattern.

H. Boker razor, with hollow ground (wheel sharpened) carbon steel blade and bone handle.

Tinplate packaging is printed in sheet form, prior to forming. This allows for the production of very high quality graphics with precise reproduction. The tin coating on the steel provides a bright metallic backdrop to the offset lithographic printed colour. Forming the steel, and adding ribs and features, helps to reduce the thickness needed to provide sturdy packaging.

Mild steel is roll formed into a trapezoid profile to make strong and lightweight sheets for roofing and cladding. It is galvanised and powder coated for protection against corrosion. While the powder coating may breakdown over decades, the zinc galvanising provides long term durability.

Kyoto tower, which stands 131 m tall, completed 1964, designed by Mamoru Yamada in collaboration with Makoto Tanahashi, is produced from welded carbon steel plate painted white

Zinc galvanising on corrugated steel after decades of exposure to weathering

High-tensile steel wire retention netting, zinc-aluminium galvanised for corrosion protection

Steel truss type structure of the Caledonian Railway Bridge, Glasgow, Scotland, designed by D. A. Matheson, completed 1905.

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.

Cross-section of a hollow composite blade, moulded with the use of a bladder, revealing the layers of super tough aramid inside the high modulus carbon fibre skin, with an inlaid stainless steel leading edge.

Handblown borosilicate glass baubles, with gold leaf.

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

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.

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

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

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

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

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.

Circular knitting machine, used to make socks, featuring a titanium nitride (TiN) coated steel collar, for enhanced wear resistance

Tokyo Gate Bridge, completed 2012, is constructed from BHS500, a type of bridge high performance steel, coated with fluoroethylene vinyl ether (FEVE). The Lumiflon coating, a type of fluoropolymer, offers exceptional resistance to weathering and UV with a long service life. It provides the 25 micron topcoat on a multilayer system made up of 75 micron zinc-rich anti-corrosion primer and 120 micron epoxy resin undercoat, plus 30 micron epoxy-based primer for the FEVE.


Pancras Square, London, under construction, by Eric Parry Architects, uses cor-ten high strength low alloy steel (HSLA) in the exposed structural facade.

The towers and jibs of construction cranes are typically produced with high strength low alloy (HSLA) steel trusses. The elements are welded together in sections and painted for visibility and durability.

Puma bike, by Vexed Generation and manufactured by Biomega, 2004, with a high carbon low alloy steel (chromoly) chain. Stainless steel has been tried in the same applications, but is prone to galling (wear caused by adhesion between sliding surfaces) and the surface tearing out. Image Puma.

Fulcrum sculpture, London, UK, by Richard Serra, 1987, is produced in Cor-ten high strength low alloy (HSLA) steel

Cougar Ridgeback armoured vehicle, manufactured from welded ballistic steel, designed to provide maximum protection against projectiles and explosions

Cor-Ten steel railway structure, raised from the concrete plinth to ensure surfaces are consistently exposed to weathering

Cor-Ten steel expanded mesh cladding covering a carpark