Aluminum extrusion is a widely utilized manufacturing process that involves shaping aluminum alloy by forcing it through a die to create specific cross-sectional profiles. This method is favored for its versatility, lightweight properties, and strength, making it suitable for various applications, from automotive to architectural components. However, the performance of aluminum extrusions is heavily influenced by the design guidelines followed during the extrusion process. This article explores how these guidelines affect product performance, focusing on key design considerations, best practices, and their implications on functionality and cost.