Aluminum 6061 is a precipitation-hardened alloy renowned for its exceptional strength-to-weight ratio, excellent weldability, and superior corrosion resistance. With balanced mechanical properties and proven performance across aerospace, automotive, and structural applications, it delivers reliable, high-strength components for demanding engineering environments.
Aluminum 6061 is a versatile precipitation-hardened alloy that combines magnesium and silicon as primary alloying elements to achieve exceptional mechanical properties. This heat-treatable alloy offers an outstanding balance of strength, ductility, and corrosion resistance, making it ideal for structural applications where high performance and reliability are essential. With T6 heat treatment, it achieves yield strengths up to 275 MPa while maintaining excellent weldability and machinability.
Aluminum 6061 combines exceptional strength-to-weight ratio for lightweight structural applications and superior weldability compared to other high-strength aluminum alloys, delivering outstanding corrosion resistance in marine and industrial environments for demanding applications. From rapid prototyping to production runs, teams rely on Aluminum 6061 to maintain tight tolerances while reducing assembly complexity through consolidated part designs.
EOS metal systems define the industry benchmark for direct metal laser sintering, incorporating precision optics with f-theta lenses that maintain consistent beam quality across the entire build platform. Their closed-loop powder handling and inert atmosphere control achieve oxygen levels below 0.1%, critical for reactive materials like titanium and aluminum alloys. The EOSTATE monitoring suite provides real-time melt pool analysis and automatic exposure parameter correction, ensuring aerospace-grade quality with full documentation for every layer of every part.
Build Volume
400 × 400 × 400 mm
Max part size
Lead Time
8-12 business days
Standard production
Layer Height
30-60 μm
Resolution
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Manufactured in Forge Labs' North American production centers with serialized traceability for Aluminum 6061.
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While Aluminum 6061 is traditionally a wrought alloy, processing through EOS DMLS enables complex geometries with properties approaching T6 condition after heat treatment. This familiar material provides engineers confidence in mechanical properties while gaining additive manufacturing design freedom.
DMLS processing of 6061 requires careful parameter optimization to minimize hot cracking, but delivers excellent strength-to-weight ratio for structural applications. Post-process T6 heat treatment achieves properties comparable to wrought material.
Forge Labs has developed specialized parameters for 6061 that minimize cracking while maintaining density >99%. Our heat treatment protocols achieve consistent T6 properties throughout complex geometries.
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From structural aerospace components to marine equipment, DMLS Aluminum 6061 combines trusted material properties with design freedom. Discover applications leveraging this proven alloy.
DMLS 6061 enables complex aerospace structures with predictable properties matching decades of flight heritage. The material's proven performance reduces qualification requirements.
Key Applications
Performance Data
Achieves 275 MPa yield strength (T6) meeting aerospace design allowables with 35% weight reduction through topology optimization.
Marine applications leverage 6061's excellent corrosion resistance and weldability for custom components. DMLS enables complex manifolds and consolidated assemblies for weight savings.
Key Applications
Performance Data
Maintains mechanical properties in marine environment with <0.1mm/year corrosion rate, suitable for long-term deployment.
Robotics engineers use DMLS 6061 for lightweight end effectors and structural components. The material's stiffness and machinability enable hybrid manufacturing approaches.
Key Applications
Performance Data
Elastic modulus 69 GPa provides stiffness for <0.5mm deflection in 500mm spans, critical for precision robotics.
Transportation applications use DMLS 6061 for lightweight interior components and structural elements. The material's fire resistance and strength meet industry standards.
Key Applications
Performance Data
Meets EN 45545-2 fire safety requirements while achieving 40% weight reduction versus steel components.
High-precision aluminum structural component
Structural Support Bracket
Aluminum 6061 precision machined component
Precision Manufacturing
DMLS production capabilities
Manufacturing Solutions
Aluminum 6061 delivers dependable strength and impact resistance for Aircraft structural components and frames and Automotive chassis and suspension parts, helping teams move from prototype to production with confidence.
Mechanical Properties
310 MPa
Aluminum 6061 records Tensile Strength at 310 MPa, reinforcing its mechanical properties story.
Mechanical Properties
275 MPa
Aluminum 6061 records Yield Strength (0.2% offset) at 275 MPa, reinforcing its mechanical properties story.
Mechanical Properties
350 MPa
Aluminum 6061 records Flexural Strength at 350 MPa, reinforcing its mechanical properties story.
Aluminum 6061 combines Exceptional strength-to-weight ratio for lightweight structural applications and Superior weldability compared to other high-strength aluminum alloys to support Aircraft structural components and frames and Automotive chassis and suspension parts that demand production-ready durability.
| Measurement | Aluminum 6061Base | Standard |
|---|---|---|
| Tensile Strength | 310 MPa | — |
| Yield Strength (0.2% offset) | 275 MPa | — |
| Flexural Strength | 350 MPa | — |
| Elongation at Break | 12 % | — |
| Hardness (Brinell) | 95 HB | — |
| Modulus of Elasticity | 69 GPa | — |
| Shear Strength | 205 MPa | — |
| Fatigue Strength (5×10⁸ cycles) | 95 MPa | — |
Aluminum 6061 delivers dependable strength and impact resistance for Aircraft structural components and frames and Automotive chassis and suspension parts, helping teams move from prototype to production with confidence.
Aluminum 6061 delivers exceptional mechanical performance with excellent strength characteristics, effectively handling demanding load conditions. Its balanced mechanical profile allows it to maintain structural integrity while preventing brittleness in critical applications.
These qualities make it well-suited for Aircraft structural components and frames, Automotive chassis and suspension parts, and Marine hardware and boat components, providing long-term durability in demanding environments. Aluminum 6061 maintains dimensional stability over time, ensuring consistent performance across temperature and stress variations.
This makes it a reliable choice for applications requiring precise geometries and tight tolerances across Aerospace, Automotive, and Marine. Its versatility and durability allow it to perform consistently across a wide range of mechanical applications, ensuring parts maintain their integrity under repetitive stress and environmental conditions.
Aluminum 6061 combines Exceptional strength-to-weight ratio for lightweight structural applications and Superior weldability compared to other high-strength aluminum alloys to support Aircraft structural components and frames and Automotive chassis and suspension parts that demand production-ready durability.
Key metric
310 MPa
Key metric
275 MPa
Key metric
350 MPa
Detailed mechanical measurements live in the performance dashboard above. Switch tabs to compare against other materials instantly.
Aluminum 6061 offers consistent density and surface quality so critical features hold tolerances and downstream finishing remains predictable.
Aluminum 6061 exhibits a density of 2.70 g/cm³ that contributes to lightweight yet durable parts. Its low moisture absorption ensures dimensional stability in varying environmental conditions.
These physical properties enable consistent part quality and predictable performance across Aircraft structural components and frames, Automotive chassis and suspension parts, and Marine hardware and boat components. The material's inherent characteristics minimize warpage and maintain tight tolerances throughout the part lifecycle.
For Aerospace, Automotive, and Marine, these physical attributes translate to reliable production outcomes with minimal post-processing requirements, ensuring parts meet specifications straight from the build platform.
Aluminum 6061 delivers 2.70 g/cm³ density so assemblies fit and finish without secondary rework.
Key metric
2.70 g/cm³
Key metric
43 % IACS
Key metric
0.040 Ω·mm²/m
Detailed physical properties measurements live in the performance dashboard above. Switch tabs to compare against other materials instantly.
Aluminum 6061 maintains dimensional stability through temperature swings, making it a reliable option for Aerospace and Automotive programs that see repeated thermal cycling.
Aluminum 6061 demonstrates excellent thermal stability with robust heat resistance, enabling it to maintain dimensional accuracy in elevated temperature environments. This thermal performance ensures parts retain their shape and mechanical properties even under thermal stress.
The material's thermal characteristics make it ideal for Aircraft structural components and frames, Automotive chassis and suspension parts, and Marine hardware and boat components that experience temperature fluctuations. Its ability to withstand thermal cycling without degradation ensures long-term reliability in Aerospace, Automotive, and Marine.
With an operating temperature range up to 300 °C, Aluminum 6061 provides engineers with confidence when designing parts for thermally demanding applications, from under-hood automotive components to industrial equipment exposed to heat sources.
Aluminum 6061 maintains geometry with a Service Temperature of 300 °C, protecting dimensional integrity during heat cycling.
Key metric
582 °C
Key metric
652 °C
Key metric
300 °C
Detailed thermal properties measurements live in the performance dashboard above. Switch tabs to compare against other materials instantly.
Equip your team with certification packs, design guides, and spec sheets tailored to Aluminum 6061.
Access the most recent datasheet and supporting documentation maintained by our engineering team.
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Advanced Manufacturing
Aluminum 6061 is manufactured using Direct Metal Laser Sintering (DMLS) technology, providing unmatched strength and precision for mission-critical applications.
Aluminum 6061 is printed on EOS M-series production systems with real-time melt pool monitoring, guaranteeing aerospace-grade density and fatigue performance for tooling and end-use components.
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