How do you calculate aluminum extrusion cost?

Multiply extruded weight by the all-in price per pound, then by the share of the order priced now, and add the die and setup charge. With 5,000 lb at $2.50/lb fully priced plus a $900 die charge, that is $12,500 + $900 = $13,400.

What is included in the all-in price per pound?

It bundles billet/metal cost (often tied to the Midwest premium plus LME), press conversion, alloy and temper adders, scrap offal credit, and any standard finishing. Pull each line from the quote and blend it into one number — here $2.50/lb.

Why is my cost per pound higher than the quoted price?

The die and setup charge spreads across the run. At 5,000 lb the $900 die adds $0.18/lb, lifting the effective rate from $2.50 to $2.68 per pound. The smaller the order, the bigger that tooling impact.

How does order size affect extrusion cost per pound?

Metal cost is linear with weight, but the fixed die charge is not. Doubling the run to 10,000 lb halves the tooling adder to $0.09/lb, which is why extruders quote price breaks at higher volumes.

What is the share of order priced now field for?

It lets you cost only the portion you are committing at today's metal price — useful when you lock half a blanket order and float the rest. At 100% the full 5,000 lb is priced, giving the $12,500 metal-and-conversion line.

Is a $900 die charge typical for aluminum extrusion?

Solid-profile dies commonly run $400–$1,500 and hollow/semi-hollow dies more. $900 is a reasonable mid-range solid die; always confirm whether it is a one-time charge or amortized per order.

Metals, Steel, Aluminum & Coil Processing calculator

Aluminum Extrusion Cost Calculator

Aluminum extrusion cost is the delivered price of an extruded profile order, combining the metal-plus-conversion charge (billet, press time, alloy adders, finishing) with the one-time die and setup charge amortized into the job. Estimators, buyers, and OEM purchasing teams use it to validate extruder quotes and compare profiles on a true cost-per-pound basis. It matters because tooling charges and partial-price-locks distort the headline number — a 5,000 lb order at $2.50/lb looks like $12,500 until the $900 die charge pushes the effective rate to $2.68/lb. Running it before you cut a PO keeps margin and standard cost aligned with what the press actually delivers.

What this calculator does

Estimate aluminum extrusion cost from extruded weight, an all-in price per pound that covers metal plus conversion, the share of the order priced now, and a die and setup charge.
Use it when quoting aluminum profiles and you need a per pound cost that includes the die and press setup, not just the metal.
It computes total aluminum extrusion cost as extruded weight times all-in price per pound times the priced share, plus the die and setup charge, and reports the resulting effective cost per pound.

Formula used

Metal and conversion cost = extruded weight × all-in price per pound × share of order priced now
Total aluminum extrusion cost = metal and conversion cost + die and setup charge

Inputs explained

Extruded weight:
All-in price per pound:
Share of order priced now:
Die and setup charge:

How to use the result

Use it when quoting or comparing extrusion suppliers, validating a new die's amortization across a first production run, or setting a standard cost before releasing the order.
It treats the all-in price as a single blended rate; if your quote breaks out billet, scrap credit, alloy adders, and anodize separately, blend them into the per-pound figure first or the total will be wrong.

Current U.S. benchmarks

The producer price index for steel mill products stands at 348.53 (BLS, May 2026), up 6.7% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The producer price index for aluminum mill shapes stands at 404.859 (BLS, May 2026), up 36.8% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The producer price index for copper and brass mill shapes stands at 559.593 (BLS, May 2026), up 76.8% from a year earlier. Quotes priced off last quarter's material cost miss this move. Global copper trades at $13,484 per tonne (IMF via FRED, May 2026).

Common questions

How do you calculate aluminum extrusion cost? Multiply extruded weight by the all-in price per pound, then by the share of the order priced now, and add the die and setup charge. With 5,000 lb at $2.50/lb fully priced plus a $900 die charge, that is $12,500 + $900 = $13,400.
What is included in the all-in price per pound? It bundles billet/metal cost (often tied to the Midwest premium plus LME), press conversion, alloy and temper adders, scrap offal credit, and any standard finishing. Pull each line from the quote and blend it into one number — here $2.50/lb.
Why is my cost per pound higher than the quoted price? The die and setup charge spreads across the run. At 5,000 lb the $900 die adds $0.18/lb, lifting the effective rate from $2.50 to $2.68 per pound. The smaller the order, the bigger that tooling impact.
How does order size affect extrusion cost per pound? Metal cost is linear with weight, but the fixed die charge is not. Doubling the run to 10,000 lb halves the tooling adder to $0.09/lb, which is why extruders quote price breaks at higher volumes.
What is the share of order priced now field for? It lets you cost only the portion you are committing at today's metal price — useful when you lock half a blanket order and float the rest. At 100% the full 5,000 lb is priced, giving the $12,500 metal-and-conversion line.

Last reviewed 2026-05-12.