Primary process: Extrusion. The full route, materials, tolerances and design tips for a mullion, with an indicative cost.
ExtrusionPrimary process
Bulk formingFamily
6Route steps
+/-0.2mmTypical tol.
A mullion is primarily made by Extrusion. Extrusion pushes heated metal through a shaped die to produce a long part with a constant cross section, like toothpaste from a tube. Below is the full route to make a mullion, the materials it suits, the tolerances to expect and the main design points. The route is free, from the finder.
Step by step
How a mullion is made
The usual route, raw material to finished part. The amber step is where the mullion gets its basic shape.
Feedstock
Start from cast billet, bloom or slab.
Extrusion
Form the mullion as a continuous profile or stock and cut it to length.
Tooling Low to medium (die) Tolerance ±0.1 to 0.3mm Lead 2 to 6 weeks
Cut to size
Saw or shear the stock to the lengths you need.
Secondary work
Machine, drill or bend wherever the raw section is not yet final.
Tooling None Tolerance ±0.125mm, to ±0.025mm Lead 1 to 10 days
Finish
Deburr and, for aluminium, anodise; otherwise plate or coat.
Tooling Low Tolerance adds microns Lead days
Inspection
Verify section, straightness and length.
Need the real cost for a mullion? The free route above is yours. Unlock the full dossier to quote and source it.
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials
Materials for a mullion
Grade
Why it suits this
Aluminium 6063
Great extrudability, finish
Aluminium 6061
Structural
PVC/plastic
Cheap profiles
Design
Design tips
General pointers. The full design-for-manufacturing list for a mullion is in the dossier.
Unbalanced wall thickness.Even the section.
Sharp corners.Add radii.
Cost
What a mullion should cost
Constant cross-section profiles (alu especially); cheap die, priced largely by weight per metre.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for a mullion at your volume, in your currency, are in the dossier.
MODEL EST.
$2.6 to 6.2per part at 100 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
GET THE FULL DOSSIER
Everything you need to quote and source it
The free route above is yours. To actually put a number on a mullion and buy it well:
Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
A quote checker that tells you if a supplier quote is fair, and the red flags to watch
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A mullion is primarily made by extrusion. The route is: Feedstock; Extrusion; Cut to size; Secondary work; Finish; Inspection.
What does a mullion cost?
It depends on size, tolerance and volume. As a rough ballpark it starts around $2.6 to 6.2 per part at 100 off and falls with quantity. The dossier gives should-cost at your exact volume and currency. A model estimate, not a quote.
What material is a mullion made from?
Common choices are Aluminium 6063; Aluminium 6061; PVC/plastic.
What is the main process for a mullion?
Extrusion. Aluminium and other profiles: frames, heat sinks, rails and trim in long runs.
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
