How thin can an aluminium tube be?

For design engineers focused on finding bespoke aluminium tubes that can reduce weight, save space or improve component performance, thinner-wall aluminium tube can offer significant advantages across a range of products with varying requirements.

Many industries, including medical, automotive, defence and other precision engineering sectors, require different thin-wall specifications. The wall thickness will depend on the application, dimensions, tolerances, and performance requirements of the finished component.

To produce thin-wall tubes, a process of cold drawing can be used. This is done by pulling aluminium tubes through specialised tooling to reduce the wall thickness. The resulting thickness can play an important role in the overall design, particularly where strength, stiffness, weight and dimensional accuracy need to be carefully balanced.

At Spartal, we manufacture precision drawn aluminium tube with wall thickness down to approximately 0.25mm. For larger diameter applications, we can draw thin-wall tubes from 100mm to 150mm diameter, with walls approximately 0.95 to 1.00mm.

Reducing wall thickness does not mean compromising performance. In fact, thin-wall can be produced with different alloys and tempers, allowing the specification to achieve an effective balance between stiffness, strength and weight.

When working with bespoke specifications for thin-wall tube, tolerances can also be a critical consideration. Very tight tolerances may be required where tubes form part of a telescopic assembly, machined component or precision interface.

As specialists in cold drawn aluminium tubing, we can discuss and advise on tube specification based on your individual needs. Rather than working only to standard tube sizes, we can produce bespoke, non-standard tubes based on factors such as diameter, wall thickness, alloy, temper and tolerance.

If you are working on a new component or reviewing an existing design, our team is ready to discuss your requirements. https://spartal.co.uk/contact-us/

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Spartal Quantity

Please let us know your anticipated or actual usage. This helps us determine the most appropriate manufacturing route and ensure we provide a suitable commercial offer for your needs.

Spartal Sizes

Ideally state you outside diameter, internal diameter, wall size & length. If you need a different shape ie. Oval / rectangle, please make a note in the comments box below

Spartal Fabrication

Is further fabrication required?
See our Engineered Components section

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Spartal Finish

Does your section require a surface finish?
The two most common options are anodising and powder coating. You can find more details on these treatments within our Surface Treatments section.

If you’d prefer your section supplied in mill finish, please let us know if you plan to surface treat it later. This helps us ensure we recommend the most suitable product.

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Spartal Alloys

1000 Series:
Pure aluminium, excellent corrosion resistance, low strength.
2000 Series:
High-strength aluminium-copper alloys, used in aerospace, lower corrosion resistance.
3000 Series:
Moderate strength, good corrosion resistance, used in cans and cooking utensils.
4000 Series:
Silicon alloys, good for welding, lower melting point.
5000 Series:
Magnesium alloys, excellent corrosion resistance, especially in marine environments.
6000 Series:
Magnesium-silicon alloys, versatile with good strength and corrosion resistance.
7000 Series:
High-strength aluminium-zinc alloys, used in aerospace and high-performance applications.

Each series has its own unique properties, making them suitable for different applications depending on the desired balance of strength, corrosion resistance, workability, and other factors.