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2020 vs 8020 Aluminum Extrusions: A Comprehensive Analysis


Aluminum extrusions are critical components in various industries due to their versatility, strength, and ease of use. Among the numerous types of extrusions available, 2020 and 8020 aluminum extrusions are particularly popular.

This materials guide provides a comprehensive comparison of 2020 and 8020 aluminum extrusions, examining their characteristics, applications, advantages, and limitations to help users make informed decisions for their projects.

Understanding Aluminum Extrusions

Aluminum extrusions are manufactured by pushing aluminum alloy through a die to create specific cross-sectional shapes. These extrusions are characterized by their T-slot design, which allows for easy assembly and modular construction. The naming conventions, such as 2020 and 8020, typically refer to the dimensions and types of profiles available in these extrusions.

Overview of 2020 and 8020 Aluminum Extrusions

2020 Aluminum Extrusion

The 2020 aluminum extrusion refers to a profile that is 20mm x 20mm in cross-sectional dimensions. It is part of the metric series of extrusions and is commonly used in smaller-scale projects and applications requiring lightweight and compact structural elements.

  • Profile Size: 20mm x 20mm
  • T-Slot Size: 6mm
  • Material: Usually made from 6063-T5 aluminum alloy
  • Weight: Approximately 0.65 kg/m


2020 aluminum extrusions are characterized by their balance of strength and lightweight properties. The 6063-T5 aluminum alloy used in these profiles provides good mechanical properties and excellent corrosion resistance.

  • Tensile Strength: Approximately 190 MPa (27,500 psi)
  • Yield Strength: Approximately 160 MPa (23,200 psi)
  • Hardness: 73 Brinell


2020 aluminum extrusions are commonly used in projects that require precision and modularity but do not need to support heavy loads. Some typical applications include:

  • DIY projects and home workshops
  • 3D printer frames and enclosures
  • Light-duty machine guarding
  • Small-scale robotics
  • Educational and prototype assemblies


  • Ease of Assembly: The T-slot design allows for simple and quick assembly using standard connectors and fasteners.
  • Modularity: Components can be easily added, removed, or repositioned, making it ideal for iterative design processes.
  • Cost-Effective: Relatively low cost compared to larger profiles, suitable for hobbyists and small-scale manufacturers.
  • Lightweight: Easy to handle and transport, suitable for applications where weight savings are important.

8020 Aluminum Extrusion

The 8020 aluminum extrusion, often referred to simply as 80/20, is a trademarked product known for its T-slot framing system. The dimensions and configurations of 8020 extrusions vary widely, but they are typically part of the inch-based series, with profiles such as 10 Series (1″ x 1″) and 15 Series (1.5″ x 1.5″).

  • Profile Sizes: Commonly available in sizes such as 25mm x 25mm, 40mm x 40mm, and larger
  • T-Slot Sizes: Typically 8mm or larger, depending on the profile size
  • Material: Often made from 6105-T5 or 6061-T6 aluminum alloys
  • Weight: Varies significantly with profile size


8020 aluminum extrusions are known for their strength and durability. The 6105-T5 and 6061-T6 alloys provide excellent mechanical properties, making these extrusions suitable for heavy-duty applications.

  • Tensile Strength: Up to 290 MPa (42,000 psi) for 6061-T6
  • Yield Strength: Up to 240 MPa (35,000 psi) for 6061-T6
  • Hardness: 95 Brinell


Due to their robust nature, 8020 aluminum extrusions are used in a wide range of industrial and commercial applications, including:

  • Industrial automation and machinery frames
  • Workstations and laboratory benches
  • Heavy-duty machine guarding
  • Conveyor systems
  • Aerospace and automotive structures


  • Strength and Durability: Suitable for applications requiring high load-bearing capacity and structural integrity.
  • Versatility: Available in various sizes and configurations, catering to a broad range of engineering needs.
  • Ease of Customization: Can be easily cut, drilled, and modified to fit specific project requirements.
  • Corrosion Resistance: High resistance to environmental degradation, making it suitable for outdoor and harsh environments.

Key Differences Between 2020 and 8020 Aluminum Extrusions

Material and Strength

2020 Aluminum Extrusion:

  • Material: 6063-T5 aluminum alloy
  • Tensile Strength: Approximately 214 MPa
  • Yield Strength: Approximately 152 MPa

8020 Aluminum Extrusion:

  • Material: 6105-T5 aluminum alloy
  • Tensile Strength: Approximately 241 MPa
  • Yield Strength: Approximately 214 MPa

Analysis: 8020 extrusions, made from 6105-T5 alloy, generally offer higher tensile and yield strength compared to 2020 extrusions made from 6063-T5 alloy. This makes 8020 extrusions more suitable for applications requiring higher structural integrity and load-bearing capacity.

Dimensional Differences

2020 Aluminum Extrusion:

  • Standard cross-section of 20mm x 20mm
  • Ideal for small to medium-sized projects
  • Lightweight and easy to handle

8020 Aluminum Extrusion:

  • Varied dimensions, with common sizes including 1″ x 1″ and 1.5″ x 1.5″
  • Suitable for both small and large-scale projects
  • Offers more versatility in terms of structural applications

Analysis: The 8020 extrusions provide a broader range of dimensions and configurations, making them more versatile for different project scales and structural requirements. The standardization of 2020 extrusions to a specific size makes them ideal for uniform and compact designs.

T-Slot Design

2020 Aluminum Extrusion:

  • Features four T-slots (one on each side)
  • Suitable for lightweight assemblies and components

8020 Aluminum Extrusion:

  • Multiple T-slot configurations depending on the series (e.g., four, six, or more T-slots)
  • Allows for more complex and modular assemblies

Analysis: The T-slot design of 8020 extrusions offers greater flexibility for building modular and complex structures. The variety of T-slot configurations enhances the adaptability of the 8020 system, making it suitable for more demanding applications compared to the simpler T-slot design of 2020 extrusions.

Surface Finish

2020 Aluminum Extrusion:

  • Available in anodized or mill finish
  • Anodized finish enhances corrosion resistance and aesthetics

8020 Aluminum Extrusion:

  • Available in anodized or powder-coated finish
  • Powder coating offers additional color options and surface protection

Analysis: Both 2020 and 8020 extrusions provide high-quality surface finishes that enhance corrosion resistance and appearance. However, the availability of powder-coated finishes in 8020 extrusions offers additional customization options in terms of color and surface protection.


2020 Aluminum Extrusion:

  • Suitable for lightweight structures
  • Commonly used in 3D printer frames, small enclosures, and laboratory equipment
  • Ideal for hobbyist and DIY projects

8020 Aluminum Extrusion:

  • Used in a wide range of applications, from lightweight to heavy-duty structures
  • Commonly employed in industrial automation, machine frames, safety enclosures, and workstations
  • Suitable for both commercial and industrial applications

Analysis: While 2020 extrusions are ideal for smaller-scale and lightweight applications, 8020 extrusions cater to a broader spectrum of uses, including industrial and heavy-duty applications. The versatility of 8020 extrusions makes them a preferred choice for complex and high-load structures.

Choosing Between 2020 and 8020 Aluminum Extrusions

The choice between 2020 and 8020 aluminum extrusions depends largely on the specific requirements of the project or application.

Use 2020 Aluminum Extrusion When:

  • Working on small-scale or DIY projects.
  • Building 3D printer frames or light-duty fixtures.
  • Budget constraints are a significant factor.
  • Space is limited, and a compact solution is required.

Use 8020 Aluminum Extrusion When:

  • Building industrial automation systems, robotics, or heavy-duty structures.
  • A modular and reconfigurable framework is needed.
  • Higher strength and load-bearing capacity are required.
  • A professional finish and appearance are desired.


Both 2020 and 8020 aluminum extrusions offer unique advantages and are suitable for different applications. Understanding their properties, strengths, and limitations is crucial for selecting the right extrusion for your specific needs.