6061-header
Lightweight
Rust Free
STRONG

Laser cut 6061 aluminum, strong and light

Our laser cut 6061 aluminum is commonly found in structural applications where toughness and corrosion resistance are of high importance. That’s pretty typical for aluminum alloys in general, but what makes this 6061 series stand out is its heat-treatability. The heat-treating process, called precipitation hardening, further strengthens the alloy without robbing it of key properties.

Many of our aluminum alloys are able to withstand tremendous amounts of vibration (also known as fatigue strength) making them perfectly suited for high-impact applications such as transportation and robotics. For any of these applications 6061 aluminum is a good middle of the road alloy, pairing the strength of 7075 with the malleability of 5052.

Material Details

Details
Advertised Thickness .040″ | 1.02mm
Gauge 18
Thickness Tolerance Positive  .004″
Thickness Tolerance Negative .004″
Cutting Process Fiber Laser
Cut Tolerance .005″
Available Operations
Deburring No
Bending No
Tapping No
Powder Coating Yes
Hardware No
Design Considerations
Min Part Size .25″ x .375″
Max Part Size 44″ x 30″
Min Hole Size .014″
Min Bridge Size .016″
Tab and Slot Tolerance .010″
Min Powder Coating Part Size 1″ x 3″
Max Powder Coating Part Size 23″ x 23″
Properties
Material Composition Aluminum (Al): 95.9 – 98.6
Magnesium (Mg): 0.8 – 1.2
Silicon (Si): 0.4 – 0.8
Iron (Fe): 0 – 0.7
Copper (Cu): 0.15 – 0.4
Chromium (Cr): 0.040 – 0.35
Zinc (Zn): 0 – 0.25
Manganese (Mn): 0 – 0.15
Titanium (Ti): 0 – 0.15
Residuals: 0 – 0.15
Density 170 lb/ft^3
Tensile Strength (Ultimate) 45 ksi
Tensile Strength (Yield) 39 ksi
Shear Strength 30 ksi
Shear Modulus 3800 ksi
Fatigue Strength 14 ksi
Brinell Hardness 93
Elongation at Break 10%
Elastic Modulus 10000 ksi
Poisson’s Ratio .33
Thermal Conductivity 97 BTU/h-ft-°F
Melting Point 1080 °F
Magnetic No
Details
Advertised Thickness .063″ | 1.6mm
Gauge 14
Thickness Tolerance Positive .004″
Thickness Tolerance Negative .004″
Cutting Process Fiber Laser
Cut Tolerance .005″
Available Operations
Deburring No
Bending No
Tapping Yes
Powder Coating Yes
Hardware No
Design Considerations
Min Part Size .25″ x .375″
Max Part Size 44″ x 30″
Min Hole Size .025″
Min Bridge Size .022″
Tab and Slot Tolerance .010″
Tab and Slot Tolerance .010″
Largest Tap M6 x 1.0
Smallest Tap M2 X 0.4
Min Tapping Part Size 1″ x 1.5″
Max Tapping Part Size 36″ x 46″
Min Powder Coating Part Size 1″ x 3″
Max Powder Coating Part Size 23″ x 23″
Properties
Material Composition Aluminum (Al): 95.9 – 98.6
Magnesium (Mg): 0.8 – 1.2
Silicon (Si): 0.4 – 0.8
Iron (Fe): 0 – 0.7
Copper (Cu): 0.15 – 0.4
Chromium (Cr): 0.040 – 0.35
Zinc (Zn): 0 – 0.25
Manganese (Mn): 0 – 0.15
Titanium (Ti): 0 – 0.15
Residuals: 0 – 0.15
Density 170 lb/ft^3
Tensile Strength (Ultimate) 45 ksi
Tensile Strength (Yield) 39 ksi
Shear Strength 30 ksi
Shear Modulus 3800 ksi
Fatigue Strength 14 ksi
Brinell Hardness 93
Elongation at Break 10%
Elastic Modulus 10000 ksi
Poisson’s Ratio .33
Thermal Conductivity 97 BTU/h-ft-°F
Melting Point 1080 °F
Magnetic No

Max Part Size42″ x 56″

Details
Advertised Thickness .080″ | 2.03mm
Gauge 12
Thickness Tolerance Positive .005″
Thickness Tolerance Negative .005″
Cutting Process Fiber Laser
Cut Tolerance .005″
Available Operations
Deburring No
Bending No
Tapping Yes
Powder Coating Yes
Hardware No
Design Considerations
Min Part Size .25″ x .375″
Max Part Size 44″ x 30″
Min Hole Size .032″
Min Bridge Size .028″
Tab and Slot Tolerance .010″
Largest Tap M6 x 1.0
Smallest Tap M2 X 0.4
Min Tapping Part Size 1″ x 1.5″
Max Tapping Part Size 36″ x 46″
Min Powder Coating Part Size 1″ x 3″
Max Powder Coating Part Size 23″ x 23″
Properties
Material Composition Aluminum (Al): 95.9 – 98.6
Magnesium (Mg): 0.8 – 1.2
Silicon (Si): 0.4 – 0.8
Iron (Fe): 0 – 0.7
Copper (Cu): 0.15 – 0.4
Chromium (Cr): 0.040 – 0.35
Zinc (Zn): 0 – 0.25
Manganese (Mn): 0 – 0.15
Titanium (Ti): 0 – 0.15
Residuals: 0 – 0.15
Density 170 lb/ft^3
Tensile Strength (Ultimate) 45 ksi
Tensile Strength (Yield) 39 ksi
Shear Strength 30 ksi
Shear Modulus 3800 ksi
Fatigue Strength 14 ksi
Brinell Hardness 93
Elongation at Break 10%
Elastic Modulus 10000 ksi
Poisson’s Ratio .33
Thermal Conductivity 97 BTU/h-ft-°F
Melting Point 1080 °F
Magnetic No
Details
Advertised Thickness .125″ | 3.18mm
Gauge 8
Thickness Tolerance Positive .006″
Thickness Tolerance Negative .006″
Cutting Process Fiber Laser
Cut Tolerance .005″
Available Operations
Deburring No
Bending No
Tapping Yes
Powder Coating Yes
Hardware No
Design Considerations
Min Part Size .25″ x .375″
Max Part Size 44″ x 30″
Min Hole Size .050″
Min Bridge Size .044″
Tab and Slot Tolerance .010″
Largest Tap M10 x 1.5
Smallest Tap M2 X 0.4
Min Tapping Part Size 1″ x 1.5″
Max Tapping Part Size 36″ x 46″
Min Powder Coating Part Size 1″ x 3″
Max Powder Coating Part Size 23″ x 23″
Properties
Material Composition Aluminum (Al): 95.9 – 98.6
Magnesium (Mg): 0.8 – 1.2
Silicon (Si): 0.4 – 0.8
Iron (Fe): 0 – 0.7
Copper (Cu): 0.15 – 0.4
Chromium (Cr): 0.040 – 0.35
Zinc (Zn): 0 – 0.25
Manganese (Mn): 0 – 0.15
Titanium (Ti): 0 – 0.15
Residuals: 0 – 0.15
Density 170 lb/ft^3
Tensile Strength (Ultimate) 45 ksi
Tensile Strength (Yield) 39 ksi
Shear Strength 30 ksi
Shear Modulus 3800 ksi
Fatigue Strength 14 ksi
Brinell Hardness 93
Elongation at Break 10%
Elastic Modulus 10000 ksi
Poisson’s Ratio .33
Thermal Conductivity 97 BTU/h-ft-°F
Melting Point 1080 °F
Magnetic No
Details
Advertised Thickness .187″ | 4.75mm
Gauge N/A
Thickness Tolerance Positive .009″
Thickness Tolerance Negative .009″
Cutting Process Fiber Laser
Cut Tolerance .005″
Available Operations
Deburring No
Bending No
Tapping Yes
Powder Coating Yes
Hardware No
Design Considerations
Min Part Size .5″ x .5″
Max Part Size 44″ x 30″
Min Hole Size .075″
Min Bridge Size .065″
Tab and Slot Tolerance .015″
Largest Tap 1/2 – 20
Smallest Tap 4 – 40
Min Tapping Part Size 1″ x 1.5″
Max Tapping Part Size 36″ x 46″
Min Powder Coating Part Size 1″ x 3″
Max Powder Coating Part Size 23″ x 23″
Properties
Material Composition Aluminum (Al): 95.9 – 98.6
Magnesium (Mg): 0.8 – 1.2
Silicon (Si): 0.4 – 0.8
Iron (Fe): 0 – 0.7
Copper (Cu): 0.15 – 0.4
Chromium (Cr): 0.040 – 0.35
Zinc (Zn): 0 – 0.25
Manganese (Mn): 0 – 0.15
Titanium (Ti): 0 – 0.15
Residuals: 0 – 0.15
Density 170 lb/ft^3
Tensile Strength (Ultimate) 45 ksi
Tensile Strength (Yield) 39 ksi
Shear Strength 30 ksi
Shear Modulus 3800 ksi
Fatigue Strength 14 ksi
Brinell Hardness 93
Elongation at Break 10%
Elastic Modulus 10000 ksi
Poisson’s Ratio .33
Thermal Conductivity 97 BTU/h-ft-°F
Melting Point 1080 °F
Magnetic No
Details
Advertised Thickness .250″ | 6.35mm
Gauge N/A
Thickness Tolerance Positive .027″
Thickness Tolerance Negative .027″
Cutting Process Fiber Laser
Cut Tolerance .005″
Available Operations
Deburring No
Bending No
Tapping Yes
Powder Coating Yes
Hardware No
Design Considerations
Min Part Size .5″ x .75″
Max Part Size 44″ x 30″
Min Hole Size .088″
Min Bridge Size .095″
Tab and Slot Tolerance .035″
Largest Tap 1/2 – 20
Smallest Tap 4 – 40
Min Tapping Part Size 1″ x 1.5″
Max Tapping Part Size 36″ x 46″
Min Powder Coating Part Size 1″ x 3″
Max Powder Coating Part Size 23″ x 23″
Properties
Material Composition Aluminum (Al): 95.9 – 98.6
Magnesium (Mg): 0.8 – 1.2
Silicon (Si): 0.4 – 0.8
Iron (Fe): 0 – 0.7
Copper (Cu): 0.15 – 0.4
Chromium (Cr): 0.040 – 0.35
Zinc (Zn): 0 – 0.25
Manganese (Mn): 0 – 0.15
Titanium (Ti): 0 – 0.15
Residuals: 0 – 0.15
Density 170 lb/ft^3
Tensile Strength (Ultimate) 45 ksi
Tensile Strength (Yield) 39 ksi
Shear Strength 30 ksi
Shear Modulus 3800 ksi
Fatigue Strength 14 ksi
Brinell Hardness 93
Elongation at Break 10%
Elastic Modulus 10000 ksi
Poisson’s Ratio .33
Thermal Conductivity 97 BTU/h-ft-°F
Melting Point 1080 °F
Magnetic No
Details
Advertised Thickness .375″ | 9.53mm
Gauge N/A
Thickness Tolerance Positive .033″
Thickness Tolerance Negative .033″
Cutting Process Fiber Laser
Cut Tolerance .005″
Available Operations
Deburring No
Bending No
Tapping Yes
Powder Coating Yes
Hardware No
Design Considerations
Min Part Size .75″ x 1″
Max Part Size 44″ x 30″
Min Hole Size .131″
Min Bridge Size .143″
Tab and Slot Tolerance .040″
Largest Tap 1/2 – 20
Smallest Tap 8 – 32
Min Tapping Part Size 1″ x 1.5″
Max Tapping Part Size 36″ x 46″
Min Powder Coating Part Size 1″ x 3″
Max Powder Coating Part Size 23″ x 23″
Properties
Material Composition Aluminum (Al): 95.9 – 98.6
Magnesium (Mg): 0.8 – 1.2
Silicon (Si): 0.4 – 0.8
Iron (Fe): 0 – 0.7
Copper (Cu): 0.15 – 0.4
Chromium (Cr): 0.040 – 0.35
Zinc (Zn): 0 – 0.25
Manganese (Mn): 0 – 0.15
Titanium (Ti): 0 – 0.15
Residuals: 0 – 0.15
Density 170 lb/ft^3
Tensile Strength (Ultimate) 45 ksi
Tensile Strength (Yield) 39 ksi
Shear Strength 30 ksi
Shear Modulus 3800 ksi
Fatigue Strength 14 ksi
Brinell Hardness 93
Elongation at Break 10%
Elastic Modulus 10000 ksi
Poisson’s Ratio .33
Thermal Conductivity 97 BTU/h-ft-°F
Melting Point 1080 °F
Magnetic No
Details
Advertised Thickness .500″ | 12.7mm
Gauge N/A
Thickness Tolerance Positive .043″
Thickness Tolerance Negative .043″
Cutting Process Fiber Laser
Cut Tolerance .005″
Available Operations
Deburring Yes
Bending No
Tapping Yes
Powder Coating Yes
Hardware No
Design Considerations
Min Part Size .75″ x 1″
Max Part Size 44″ x 30″
Min Hole Size .170″
Min Bridge Size .190″
Tab and Slot Tolerance .050″
Largest Tap 1/2 – 20
Smallest Tap 10 – 32
Min Tapping Part Size 1″ x 1.5″
Max Tapping Part Size 36″ x 46″
Min Powder Coating Part Size 1″ x 3″
Max Powder Coating Part Size 23″ x 23″
Min Deburring Part Size .949″ x 3″
Max Deburring Part Size 24″ x 46″
Properties
Material Composition Aluminum (Al): 95.9 – 98.6
Magnesium (Mg): 0.8 – 1.2
Silicon (Si): 0.4 – 0.8
Iron (Fe): 0 – 0.7
Copper (Cu): 0.15 – 0.4
Chromium (Cr): 0.040 – 0.35
Zinc (Zn): 0 – 0.25
Manganese (Mn): 0 – 0.15
Titanium (Ti): 0 – 0.15
Residuals: 0 – 0.15
Density 170 lb/ft^3
Tensile Strength (Ultimate) 45 ksi
Tensile Strength (Yield) 39 ksi
Shear Strength 30 ksi
Shear Modulus 3800 ksi
Fatigue Strength 14 ksi
Brinell Hardness 93
Elongation at Break 10%
Elastic Modulus 10000 ksi
Poisson’s Ratio .33
Thermal Conductivity 97 BTU/h-ft-°F
Melting Point 1080 °F
Magnetic No

Common Uses

  • Construction
  • Stressed components
  • Automotive
  • Aerospace structural
  • Industrial applications
  • Robotics

Minimum Hole Size

To ensure the best quality for your parts, we recommend no less than 50% material thickness for all holes. See the images below for more detail. The largest hole is 70% material thickness. Each hole decresases in size by 10%.

.500″ 6061 Aluminum

Hole diameters are based on material thickness.
50% diameter = 50% material thickness

.500" primary face

.500" primary face

.500" back side

.500" back side

.500" front, angle

.500" front, angle

.500" back, angle

.500" back, angle

.375″ 6061 Aluminum

 

Hole diameters are based on material thickness.
50% diameter = 50% material thickness

.375" primary face

.375" primary face

.375" back side

.375" back side

.375" front, angle

.375" front, angle

.250″ 6061 Aluminum

 

Hole diameters are based on material thickness.
50% diameter = 50% material thickness

.250" primary face

.250" primary face

.250" back side

.250" back side

.250" front, angle

.250" front, angle

.250" back, angle

.250" back, angle

.187″ 5052 Aluminum

Hole diameters are based on material thickness.
50% diameter = 50% material thickness

.120" primary face

.120" primary face

.120" back side

.120" back side

.120" front, angle

.120" front, angle

.120" back, angle

.120" back, angle

.120″ 6061 Aluminum

Hole diameters are based on material thickness.
50% diameter = 50% material thickness

.120" primary face

.120" primary face

.120" back side

.120" back side

Our laser cut aluminum is guaranteed

We guarantee awesome quality parts. If you’re not 100% happy, we’ll give you a refund or remake on the spot – no questions, no hassle.

Material Charts and Guidelines

Min/Max Part Sizes

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Processing Min/Max Part Sizes

VIEW

Density Guidelines

VIEW

Design Guidelines

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