by Sam Brown
Aluminium is a widely used material in healthcare manufacturing thanks to its versatility and cost-effectiveness. Choosing the right aluminium grade can improve quality, consistency, and lead times for your medical parts. This guide will help you understand the best aluminium medical grades for your device applications.
Aluminium in medical devices offers the perfect combination of strength, light weight, and corrosion resistance. You must balance factors like machinability, finishing ability, and material strength to make the best choice. Read on to learn how to specify the right aluminium for your next project.
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Why Use Aluminium in Medical Device Manufacturing?
Aluminium has many advantages when used in medical manufacturing. Its strength-to-weight ratio, excellent corrosion resistance, and machinability make it an attractive material for many medical designs. Aluminium medical parts help to lower overall product costs while maintaining high performance standards.
You will often find aluminium in surgical tools, imaging equipment housings, diagnostic frames, and laboratory systems. The natural corrosion resistance of aluminium makes it suitable for use in sterile and high-humidity environments. Treatments like anodising can further enhance durability and surface finish in sensitive medical settings.
Choosing the right aluminium machining service ensures that your parts meet the highest medical standards for precision, consistency, and cleanliness. Precision is key when producing components that impact patient safety and device performance. Trusted partners like Penta Precision specialise in delivering the right aluminium solutions for medical OEMs.
Choosing the Right Aluminium Alloy for Medical Parts
Selecting the correct aluminium alloy is critical when designing medical components. There is no one-size-fits-all option like stainless steel’s 316L grade, so you must evaluate the unique requirements of your part. Different aluminium grades vary significantly in strength, corrosion resistance, and finish quality.
When deciding between alloys, think about whether your part needs to withstand structural loads, repeated sterilisation, or aesthetic scrutiny. Some grades offer unbeatable strength but are harder to anodise, while others provide superb cosmetic finishes with slightly lower toughness. Balancing all these factors will help you choose the right aluminium in medical devices.
Understanding the differences between alloys is essential, and consulting a full aluminium materials guide helps you select the most suitable grade for your application. Working with a specialist like Penta Precision ensures that technical advice supports your choice of material. We help you weigh up strength, cost, lead time, and finishing options before production begins.
2014A (L93, L157, L168) – Extremely Strong Aluminium Alloy
2014A aluminium is a very strong material often selected for aerospace and defence applications. It retains excellent strength after heat treatment and offers durability that rivals low-carbon steels. However, it does not perform as well as other alloys in terms of corrosion resistance.
Because of its 4–5% copper content, 2014A can suffer from reduced ductility and poor natural corrosion protection. It is also difficult to anodise well, with only hard anodising being a viable option for limited surface finishing. Welding, brazing, and soldering are generally not recommended for this alloy in medical manufacturing.
Despite its limitations, 2014A is an excellent choice for high-strength internal components in medical equipment. You can depend on its durability where strength matters more than appearance. Selecting it carefully ensures reliability without overspending on unnecessary cosmetic finishes.
Strengths and Limitations
2014A’s main advantage is its extremely high strength-to-weight ratio. It offers great toughness after heat treatment, making it suitable for parts subject to heavy mechanical loads. On the downside, its poor corrosion resistance limits it to internal, non-visible uses.
You cannot reliably weld or anodise 2014A for cosmetic purposes. Iridite NCP and Surtec 650 coatings are preferred if additional protection is needed. Hard anodising is possible but should be reserved for darker colours to achieve consistent finishing.
Understanding its metallurgical properties helps you specify it only for the right applications. You should consider 2014A when weight-saving combined with high strength is crucial. However, it is not the best choice for external or highly visible components in aluminium medical parts.
Best Medical Applications
2014A is ideal for rugged, concealed internal frames, brackets, or mechanical linkages in medical equipment. It is used in heavy-duty support structures where cosmetic appearance is not critical. Internal load-bearing devices often benefit from this alloy’s superior strength.
Medical diagnostic machines or surgical robots sometimes require internal frameworks machined from 2014A. Its toughness gives designers confidence in the long-term reliability of moving or load-bearing assemblies. Specifying this material wisely ensures both durability and cost efficiency in aluminium medical applications.
7075 (L95) Aluminium – Strong, Refined With Consistent Finishing
7075 aluminium is one of the strongest commercially available alloys used in aerospace and medical applications. It offers outstanding tensile strength while maintaining good machinability and decent corrosion resistance. 7075 aluminium medical components are known for their reliability under high loads.
Compared to 2014A, 7075 provides better surface finishing options and tighter metallurgical controls. It can be anodised for cosmetic purposes more consistently than 2014A. This makes it a strong contender for medical applications where both strength and appearance are important.
Understanding the different tempers available for 7075 is crucial for your application. Some versions optimise strength, while others prioritise stress-corrosion resistance. Let’s take a closer look at the strengths, limitations, and medical uses of this powerful aluminium alloy.
Strengths and Limitations
7075 offers excellent strength comparable to many steels while remaining much lighter in weight. It machines well with standard tools and can achieve tight tolerances critical in medical manufacturing. However, certain tempers like T6 can be vulnerable to stress-corrosion cracking in harsh environments.
Choosing the right temper, such as T73 or T76, improves resistance to stress-related failures. The T6 version offers maximum strength but lower corrosion resistance, depending on your project needs. The overall consistency in finishing makes 7075 a favourite for demanding healthcare products.
You should remember that 7075 costs around 10% more than 2014A but offers better versatility. The ability to produce both strong and visually appealing components adds significant value. If you are balancing strength, weight, and finish quality, 7075 is an excellent choice for aluminium medical designs.
Best Medical Applications
7075 aluminium is ideal for external medical components requiring both strength and an attractive appearance. It is often specified for surgical frames, diagnostic machine housings, and portable medical equipment bases. High-load moving parts where cosmetic finish matters are a perfect match for this alloy.
Its strength makes it popular for robotic surgical arms and precision imaging machine structures. 7075 is also widely used in mobile medical platforms and rehabilitation equipment requiring robust but lightweight frames. It offers an excellent balance between mechanical performance and visual appeal for demanding healthcare devices.
6082 L111 bar, L113 sheet, L114 tube, L115 plate – Commercial Grade Aluminium
6082 is the most commonly used commercial-grade aluminium alloy in general industry and is gaining popularity in healthcare. It offers a good balance between strength, corrosion resistance, and cost, making it very versatile. 6082 is widely available, which means faster sourcing and reduced project lead times.
Although slightly less pure than aerospace grades, 6082 still meets many critical structural requirements. It is excellent for applications where mechanical loads must be supported without the need for exotic materials. Aluminium medical parts made from 6082 can provide excellent durability at a competitive price.
6082 machines easily with standard tooling, making it ideal for efficient, high-volume production. Its general availability means it is easier to machine and finish reliably compared to more specialised alloys. Let’s break down its key strengths and best medical applications.
Strengths and Limitations
6082 is known for being very easy to machine with standard tooling, which reduces production time and cost. It has high corrosion resistance, especially when anodised or coated with Iridite NCP or Surtec 650. However, compared to aerospace alloys, it has slightly lower strength and purity.
Its excellent machinability means faster production cycles, fewer tooling changes, and better cost control. 6082 anodises well, with both sulphuric and hard anodising options available for medical applications. While its mechanical properties are not the highest, its balance between performance and economy is ideal.
You can maximise its benefits by using it for non-body-contact medical parts. Components made from 6082 can be sterilised and cleaned without major degradation. It is a practical material that helps keep medical project costs under control.
Best Medical Applications
6082 is perfect for medical diagnostic frames, non-critical housings, transport systems, and support structures. It is often used in laboratory equipment, medical trolleys, and mobile diagnostic machines. Its good anodising characteristics make it suitable for parts that must be both strong and clean looking.
You can also use it for base plates, machine guards, and secondary mechanical systems inside larger medical devices. 6082 performs well in applications that require frequent cleaning and moderate mechanical loads. Its strength-to-cost ratio makes it a reliable and economical workhorse in medical product design.
5083 Marine-Grade Aluminium – Resistant To Chemicals
5083 aluminium is famous for its excellent resistance to seawater and industrial chemicals. Although it is not as strong as some aerospace grades, its corrosion resistance is among the best. For applications where chemical exposure is a factor, 5083 aluminium medical parts are an excellent solution.
This grade is a cast tooling plate, meaning it has a uniform internal structure and low internal stresses. It machines consistently and offers reliable flatness across large surface areas. Let’s look at why this alloy is so valuable for certain medical environments.
Strengths and Limitations
5083 aluminium offers superior corrosion resistance, especially against chemicals, humidity, and saltwater. It has good mechanical strength but is not heat treatable like some other alloys. Its machinability is good, although fine threads may require reinforcement using helicoils or wire inserts.
Because it is a cast plate, 5083 offers excellent dimensional stability and flatness. It is usually cheaper than aerospace aluminium grades, offering good value for non-critical structures. However, it is not recommended for high-temperature applications above 65°C.
Despite this limitation, 5083's corrosion resistance and machining consistency make it a top choice. You should consider it for chemical and marine-exposed medical products. It remains one of the best aluminium options where chemical resistance is non-negotiable.
Best Medical Applications
5083 aluminium is ideal for chemical processing equipment, laboratory benches, and mobile cleanroom platforms. It is often used in casings and enclosures for medical equipment exposed to aggressive cleaning agents and harsh sterilisation methods. Structural frames that require excellent flatness and chemical resistance also benefit greatly from this material.
Its strength and corrosion resistance make it reliable for transport carts, tool trays, and storage systems used in hospitals and laboratories. 5083 is trusted in environments where exposure to industrial chemicals or marine conditions could damage weaker alloys. With the right design considerations, you can create long-lasting, corrosion-resistant products with 5083 aluminium medical parts.
6061 Aluminium - The Balanced Choice for Medical OEMs
6061 aluminium is a popular grade in North America and is gaining more use in the UK and Europe. It offers a good balance between strength, corrosion resistance, and machinability, making it a practical option for many medical components. 6061 aluminium medical parts provide reliable performance where moderate strength and good finish quality are required.
Although similar to 6082 in many ways, there are subtle differences in processing methods and performance that could affect your decision. 6061 is cold-processed and better suited for coatings, while 6082 is typically used where slightly higher tensile strength is needed. Cost and availability may also influence your final selection between these two close alternatives for aluminium medical designs.
Knowing when to specify 6061 over 6082 can help you optimise both your component performance and project budget. Working closely with your machining partner will ensure that material selection supports long-term reliability and cost-efficiency. Let's break down the key properties and medical uses of 6061 aluminium for OEM medical manufacturing.
Strengths and Limitations
6061 aluminium offers medium-to-high strength, excellent corrosion resistance, and good coating capabilities. It machines cleanly and accepts various finishes, including anodising and protective coatings. However, it tends to be 30% more expensive than 6082 and may be harder to source in some markets.
Its copper content is higher than 6082, making it slightly more vulnerable to corrosion if untreated. Proper surface treatments help maximise its longevity and maintain hygiene in medical environments. When aesthetics and corrosion resistance are important together, 6061 is a strong contender.
Despite its higher cost, 6061 provides predictable, consistent performance in demanding applications. It is a smart choice where a balance between strength, corrosion resistance, and appearance is needed. Knowing these factors will help you decide if 6061 fits your aluminium medical part requirements.
Best Medical Applications
6061 is commonly used for cosmetic medical housings, hand-held diagnostic tools, and enclosures requiring a high-quality finish. It is ideal for components that are exposed to regular cleaning, handling, and mechanical stresses. Its compatibility with a wide range of coatings makes it a great choice for patient-facing devices.
It is also specified for certain surgical device frames and medical carts requiring lightweight strength and durability. OEMs appreciate 6061's ability to provide strength without sacrificing finish quality. If your medical design demands aesthetics, hygiene, and durability combined, 6061 aluminium is a very solid choice.
6063 Aluminium - Ideal for Lightweight Medical Extrusions
6063 aluminium is well-known as the "architectural alloy" thanks to its excellent finish quality and corrosion resistance. It is a medium-strength aluminium ideal for extruded shapes like tubes, frames, and rails used in medical devices. 6063 aluminium medical parts are perfect when lightweight structures and great finishes are required.
This grade is easy to extrude and anodises exceptionally well, making it a favourite for medical applications where appearance matters. Although not as strong as 6061 or 6082, it still meets the needs of many support structures and lightweight medical frameworks. Selecting the right aluminium finishing service ensures that 6063 parts achieve the hygiene, durability, and cosmetic standards needed for healthcare environments.
6063 strikes an important balance between cost, ease of processing, and attractive appearance. It is widely used when lightweight frames must remain durable and visually professional in clinical settings. Let's review its strengths and best uses in healthcare product design.
Strengths and Limitations
6063 aluminium has excellent surface finishing capabilities, making it a great choice for visible structures. It anodises well and provides high corrosion resistance when properly coated. However, its mechanical strength is lower than stronger alloys like 7075 or 6082.
It is extremely easy to extrude into custom profiles, saving manufacturing time and reducing costs. 6063 also provides decent electrical conductivity, which can be useful for certain device designs. Despite its lower strength, its lightweight properties are valued in medical framework construction.
You should specify 6063 when aesthetics, corrosion resistance, and ease of extrusion are your priorities. It is not intended for high-load structural components but performs well for medium-duty applications. Overall, 6063 is a great option for lightweight and visually critical aluminium medical parts.
Best Medical Applications
6063 is ideal for lightweight diagnostic frames, portable medical device casings, and patient support rails. It is frequently used in equipment that must be moved easily or that requires precise, attractive extruded profiles. Wheelchair components, rehabilitation frames, and lightweight diagnostic systems often specify 6063.
You can also use it for architectural features inside medical environments, such as balustrades or support rails. Its anodised finish helps maintain hygiene standards while delivering an attractive, clean appearance. Learn more about enhancing the finish of 6063 parts in our aluminium finishing service guide.
Get Penta Involved
Aluminium is one of the easiest materials to machine but requires careful material selection to achieve the best results. Different alloys behave differently during machining, finishing, and sterilisation processes, impacting your final product performance. Getting aluminium medical machining right starts with expert guidance.
Penta Precision is ISO 9001:2015 accredited for quality and specialises in precision aluminium machining services for healthcare applications. Our engineers can help you select the best alloy and advise on design improvements before production starts. We partner with you from concept to final part delivery to ensure quality, cost-efficiency, and superb service.
Depend on Penta to maintain consistency through validated manufacturing and finishing processes. We communicate clearly, take great care at every stage, and deliver consistently high-quality results. Let's collaborate to make your next medical project a success.