Aluminum pricing fluctuates weekly based on commodity markets, but understanding typical costs per profile and form helps you negotiate better deals and plan budgets accurately. Whether you need extrusions, sheet stock, or castings, suppliers price differently based on order volume, alloy grade, and mill finish. Here's what you actually pay for common aluminum products.
Pricing by Profile Type
Extruded aluminum typically ranges from $3 to $8 per pound, depending on complexity and cross-section size. Simple rectangular or circular profiles sit at the lower end; intricate custom shapes with tight tolerances cost more. T-slot framing and standard industrial extrusions run $4–$6/lb for orders under 500 pounds. Volume orders (1,000+ lbs) drop to $2.50–$4/lb as suppliers amortize tooling costs.
Sheet and plate aluminum prices vary by thickness and alloy. A quarter-inch 6061-T6 aluminum sheet runs roughly $150–$250 per sheet (typically 4×8 feet), while thinner gauge material (0.063–0.125 inches) costs $80–$180 per sheet. Specialty alloys like 7075 or 5083 command 20–40% premiums. If you're buying cut-to-length blanks, expect an additional $0.50–$2.00 per piece for shearing and handling.
Structural angles, channels, and beams (hot-rolled equivalent profiles) cost $2.50–$5.50/lb. A 2×2×¼ inch aluminum angle might run $180–$280 for a 20-foot length. Suppliers often sell in standard 20-foot lengths, so partial lengths incur cut charges of $15–$50 depending on the mill.
Casting and Forgings
Aluminum castings vary dramatically by method. Sand castings typically cost $8–$18/lb, with a 10-pound part running $80–$180 plus mold charges ($200–$1,000 one-time). Die castings suit high-volume runs (1,000+ pieces) and cost $4–$12 per part once you've invested in tooling ($3,000–$15,000). Investment castings are pricier at $12–$25/lb but handle fine details better.
Aluminum forgings range from $10–$30/lb and require minimum orders of 50–100 pieces. Lead times typically extend 6–12 weeks for custom forgings, so plan accordingly.
Rod, Tube, and Bar Stock
Solid rods in common alloys (6061, 7075) cost $3–$7/lb depending on diameter and whether you buy full coils or cut lengths. A 1-inch diameter, 12-foot rod in 6061 typically runs $40–$80. Hollow tubes (seamless or welded) cost slightly more at $4–$8/lb because material is removed; a 1-inch OD, 16-gauge aluminum tube runs $35–$95 per 20-foot section. Custom-cut pieces add $10–$30 per cut.
Volume Discounts and Hidden Costs
Most aluminum suppliers tier pricing by order weight:
- Under 100 lbs: Base price (highest per-pound cost)
- 100–500 lbs: 5–10% discount
- 500–2,000 lbs: 10–20% discount
- 2,000+ lbs: 15–30% discount (and potential mill-direct pricing)
Don't overlook these add-ons:
- Cutting/shearing fees ($15–$50 per cut)
- Finishing (anodizing, powder coat): $1–$5/sq ft
- Delivery charges ($50–$300+ depending on weight and distance)
- Setup or handling fees for small orders
How to Get Accurate Quotes
Contact suppliers with exact specifications: alloy grade (6061, 5052, 7075), temper (annealed, T4, T6), dimensions, and quantity. Some suppliers charge for custom quotes if the job is complex; expect 2–5 business days for a response. Request pricing for multiple quantities (100 lbs, 500 lbs, 1,000 lbs) to see the discount structure—this reveals where your sweet spot lies.
Comparing quotes across multiple suppliers is essential since pricing and minimum orders vary widely. Platforms like Mercoly let you compare trusted metal and raw material suppliers in one place, saving time and helping you find the best combination of price, quality, and lead time.
Frequently Asked Questions
Q: Do I pay for scrap or trim loss? Most suppliers include 3–5% waste in their pricing for cut-to-length orders. Custom profiles may allow 5–10% trim loss depending on the contract. Always clarify this before signing.
Q: What's the typical lead time for standard profiles? Stock items (common extrusions, sheet, bar) ship within 1–2 weeks; custom or specialty alloys take 3–6 weeks depending on mill capacity.
Q: Should I buy direct from the mill or use a distributor? Mills offer better per-pound pricing on large volumes (2,000+ lbs) but require longer lead times and higher minimums. Distributors are faster and more flexible for smaller orders, though they charge a markup. Match your volume and urgency to the right channel.
Start by collecting three quotes for your exact specifications, comparing per-pound costs alongside delivery and lead times.