Explore every episode of the podcast The Shapemakers by The Aluminum Extruders Council

Host: Jason Weber, President, Aluminum Extruders Council (AEC) 
Guest: Melvin “Mel” Mitchell, EHS Director, MI Metals 

Episode Summary 

Jason sits down with longtime safety pro Melvin Mitchell to preview AEC’s upcoming Safety & HR Workshop + Plant Tour—two tightly packed days at the Westin Atlanta Airport, October 28–29. Why combine Safety and HR? Because that’s how the real world runs: overlapping responsibilities, shared culture, and one goal—send everyone home safe while building great teams. 

You’ll hear what’s on the agenda (from molten metal and maintenance safety to employment law and recruiting more women and veterans), why the Bonnell Aluminum—Noonan plant tour is a can’t-miss (three+ years with no recordable incidents), and exactly why the best ideas often spark on the post-session barstool. Register early—bus seats for the plant tour are limited, and early/group rates sweeten the deal. The event is open to members and non-members, with sponsorships available. 

Why Listen 

• Get a field-tested map of the two-track program (Safety + HR) and how they connect. 

• Learn how culture, behavior, and systems turn safety from posters into performance. 

• Steal practical ideas you can apply next shift—not next year. 

Program Highlights 

Safety Track 

• Keynote: Changing mindsets and driving a safety culture transformation (Chris Andrews, EHS Manager, Bonnell Aluminum—Noonan) 

• Workshops & Breakouts: 

• Cast house & molten metal safety (and why your scrap prep matters) 

• Emergency preparedness & first-responder training 

• Maintenance tech safety: practical risk reduction 

• Human behavior: common pitfalls and proven fixes 

• Safety panel: interactive problem-solving with peers 

HR Track 

• Leadership Keynote: “The Power Position”—shifting cultures and driving results (Emily Nichols-Mitchell, Accelerations Group) 

• Sessions: 

• Employment law essentials: ICE/I-9, workers’ comp, hot-button issues (Philip Russell, Ogletree Deakins) 

• Integrating veterans into manufacturing teams (John Buckley, Textron Aviation) 

• Reaching women in operations—expanding the talent pipeline 

• Future-of-work challenges (Performance Point LLC) 

• HR panel: candid Q&A on today’s toughest people challenges 

Plant Tour 

• Bonnell Aluminum — Noonan, GA 
  See the systems, standards, and behaviors behind 3+ years with no recordable incidents—a live look at excellence in action. 

Who Should Attend 

• Safety leaders, HR pros, operations managers, plant supervisors, and anyone who wears both hats (because… many do). 

Key Takeaways 

• Safety and HR are two sides of one culture—align them and performance compounds. 

• Behavior + systems beat posters and pep talks. 

• Peer networking accelerates solutions you can deploy immediately. 

• Seeing best-in-class operations in person changes how you lead back home. 

Logistics & Registration 

• When/Where: October 28–29, Westin Atlanta Airport (not downtown—easy in/out). 

• Plant Tour: Wednesday morning; limited coach capacity—register early to secure a seat. 

• Pricing: Early-bird and multi-attendee discounts available. 

• Open Access: AEC members and non-members welcome. 

• Sponsorships: Opportunities available for suppliers and extruders—helps offset costs and boosts visibility. 

Pro tip from Mel: Don’t leave your hotel to chance—book early. Atlanta traffic doesn’t care about your first session. 

Register early, bring your team, and claim those tour seats. 
(And if you’re a supplier or extruder, consider a sponsorship—it fuels the content and keeps costs in check.) 

https://members.aec.org/events/EventDetails.aspx?id=1970710&group=

Summary

In this conversation, Jason Weber and Mark Butterfield discuss the upcoming Aluminum Summit, highlighting its significance as a major event for the aluminum industry. They delve into the various workshops, networking opportunities, and keynote speakers that will be featured, emphasizing the importance of learning and collaboration within the industry. The discussion also touches on market trends, challenges, and the need for the next generation of professionals in the field.

Takeaways

The Aluminum Summit occurs every four years, with the next one in September.
Networking opportunities at the summit are invaluable for industry professionals.
Workshops will cover a wide range of topics, including anodizing and extrusion.
The Extrusion Excellence Workshop is a key learning opportunity for attendees.
General sessions will address critical industry issues like trade and tariffs.
The keynote speaker, Gene Marks, will provide insights on navigating economic challenges.
Focus sessions will cater to various aspects of the aluminum industry.
Understanding market trends is essential for industry growth and adaptation.
The summit aims to foster collaboration between extruders and finishers.
Encouraging the next generation of professionals is vital for the industry's future.

For details about the Aluminum Summit Visit - https://members.aec.org/page/aluminum-summit-about

Episode Summary: 

In this episode of SHAPEMAKERS, host Bennett McEvoy, President of Western Extrusions and AEC Board Member, is joined by Duncan Crowdis, former CEO of Bonnell Aluminum and AEC Workforce Development lead. Together, they shine a light on the aluminum extrusion industry’s growing need for skilled talent—and what the Council is doing about it. 

With over 175 extrusion plants operating across 37 states, the industry supports more than 40,000 U.S. jobs. But as experienced workers retire and demand for aluminum products rises, attracting and training the next generation of skilled professionals has become mission-critical. 

Bennett and Duncan dive into the AEC’s multi-year effort to launch industry-wide apprenticeship programs—starting with maintenance technicians and expanding to extrusion press operators and die technicians, two of the industry's most essential roles. Listeners will get a behind-the-scenes look at how the AEC collaborated with the U.S. Department of Labor, developed tailored training programs, and is now preparing to launch a Train-the-Trainer initiative in 2026. 

What You’ll Learn: 

• Why aluminum extrusions are everywhere—even if you don’t always see them 

• The crucial role of skilled maintenance workers and press operators 

• How apprenticeship programs are helping to future-proof the extrusion workforce 

• What’s ahead for the AEC’s Train-the-Trainer initiative 

• How companies can get involved right now 

Resources & Links: 

•   Learn more about the AEC Apprenticeship Program: www.AEC.org 

•   Contact the AEC about workforce development: info@aec.org 

•   Want to join the extrusion industry? Explore career opportunities and resources on the AEC website 

In this episode, Jason Weber and Mark Butterfield reflect on the AEC's 75th anniversary, discussing the organization's impact on the industry and the importance of adapting to change. They outline strategic planning for 2025, upcoming events, and the significance of training and development for members. The conversation also highlights the need for effective communication and member engagement, as well as the challenges posed by trade dynamics. Looking ahead, they emphasize the importance of collaboration and a unified voice within the industry.

Takeaways

• 2024 was a significant year for the AEC, marking its 75th anniversary.
• The AEC has played a crucial role in shaping the industry over the decades.
• Strategic planning for 2025 is essential to adapt to industry changes.
• Upcoming events will focus on member engagement and professional development.
• Training programs for die correctors and press operators are being developed.
• Effective communication is key to understanding member needs.
• Trade challenges remain a top priority for the AEC's strategy.
• The annual meeting serves as a vital networking opportunity for members.
• Collaboration among members enhances the value of the AEC.
• Looking forward to 2025, the AEC aims to serve its members better.

In this episode of ShapeMakers, Lynn Brown and Rue Rogers discuss the intersection of aluminum extrusion and the circular economy. They explore how aluminum can be recycled effectively, the importance of maintaining materials in circulation, and the role of scrap in the industry. The conversation highlights the sustainability initiatives within the aluminum extrusion sector and the potential for increased recycling efforts.

Takeaways

• The circular economy aims to keep materials in circulation indefinitely.
• Aluminum has a high recycling rate, with 75% still in use today.
• Recycling aluminum does not degrade its properties, allowing for high-quality applications. Aluminum can be used over and over without any degradation of properties.
• The industry uses a mix of virgin and recycled aluminum, typically around 25% virgin and 75% scrap.
• Recycled aluminum billet can be used just like billet made from prime or virgin aluminum; it does not need to be downgraded to be used in lower performance applications because of its scrap content like other materials.
• Post-consumer scrap includes materials from product end-of-life, such as old windows and doors, wheels, wire and other building components.
• Anodized aluminum can be recycled similarly to unfinished aluminum, while painted aluminum poses challenges.
• The infrastructure for collecting and processing aluminum scrap is well-established in North America.
• There is potential to increase the use of post-consumer scrap in the industry.
• Aluminum's corrosion resistance contributes to its long lifespan in applications.
• The aluminum extrusion industry is actively working on improving recycling processes.

Learn more about the Aluminum Extruders Council at aec.org

Welcome to Shape Makers, the podcast series from the Aluminum Extruders Council (AEC). AEC represents over 75% of North America's aluminum extrusion production. In this series, we explore key issues affecting extruders, suppliers, and users of aluminum extruded products. Our guest speakers dive into topics like aluminum extrusion Fairtrade cases, industry efforts to attract and retain skilled workers, how extrusion products meet stricter building and energy codes, the increasing use of extrusions in vehicles, and much more.

Join Jason Weber from the AEC as he chats with industry veteran Mark Butterfield, the newly appointed chairman of AEC. Mark shares his journey in the aluminum extrusion industry, his vision for AEC, and the importance of engaging with the Council's committees and initiatives. Learn about the rich history of the AEC, the legacy of foundational companies, and the value of networking and collaboration within the industry.

Whether you're a seasoned professional or new to the field, Shape Makers offers insights and inspiration to help you navigate the dynamic world of aluminum extrusions. So sit back, relax, and get ready to learn more about the innovations and challenges shaping the industry.

::::::::

About Mark Butterfield - President of Manufacturing, MX Holdings

With more than 30 years of experience in the aluminum extrusion industry, Mark Butterfield serves as President of Manufacturing MX holdings which includes Pennex. An established industry leader, he also serves the Aluminum Extruders Council (AEC) in multiple positions, including that of Vice Chairman of the Board of Directors, Chairman of the Automotive Committee, and Vice Chairman of Extrusion Technology 2024.

Connect with Mark on Linkedin

 Lynn Brown of the AEC and Shane Tredup of Custom Aluminum discuss decarbonization efforts in the extrusion industry, highlighting the growing demand from customers for information on carbon footprint, scope one, two, and three emissions, and decarbonization plans. 

Industry tool for aluminum extruders to track carbon emissions.

• ACC aims to create industry tool for extruders to track carbon footprint and reduce it by 20%.
• Tool to calculate carbon emissions for extruders, covering multiple products and methodologies.
• Discover the tool's capabilities, including sensitivity analysis and real-time what-if scenarios, to help extruders understand the impact of changes to their business on their carbon intensity.

The tool will be useful for extruders to understand their own situation and make improvements and plans to do a separate podcast on the tool's functionality and new guidelines for granularity and reporting.

About The AEC:

Follow AEC on LinkedIn for the latest updates and industry insights.

• Stay informed about the Aluminum Extruders Council by visiting aec.org and following us on Twitter.

Stay Tuned for More SHAPEMAKERS: Don't miss out on future episodes of SHAPEMAKERS where we continue to explore the stories, innovations, and trends shaping industries worldwide. Subscribe on Apple Podcasts, Spotify, or your favorite podcast platform.

Thank you for joining us on this enlightening journey through the world of aluminum extrusion. Until next time, keep shaping the future!

Welcome back to another riveting episode of SHAPEMAKERS, where we explore the fascinating world of shaping industries and innovations. In this special edition, Jason Weber, the VP of Operations and Government Affairs for the Aluminum Extruders Council (AEC), sits down with our distinguished guest Rob Nelson Executive Vice President at ALMAG Aluminum.

ALMAG ALUMINUM 

ALMAG’s history began in 1953, when Edward Peacock founded ALMAG Aluminum and Magnesium Ltd. manufacturing decorative door grilles. ALMAG’s first aluminum extrusion press started production in 1959.

Mr. Peacock envisioned a prosperous business with an ambition to build good products with good people and repeat business. Today, under the leadership of his son, Bob, our passion for quality and service remains strong.

For more on ALMAG visit - ALMAG Aluminum / Made possible. – Design • Extrude • Fabricate • Finish

About The AEC:

Follow AEC on LinkedIn for the latest updates and industry insights.

• Stay informed about the Aluminum Extruders Council by visiting aec.org and following us on Twitter.

Stay Tuned for More SHAPEMAKERS: Don't miss out on future episodes of SHAPEMAKERS where we continue to explore the stories, innovations, and trends shaping industries worldwide. Subscribe on Apple Podcasts, Spotify, or your favorite podcast platform.

Thank you for joining us on this enlightening journey through the world of aluminum extrusion. Until next time, keep shaping the future!

Jason Weber visits with Prof. Lorenzo Donati about the upcoming ET'24 In-Conjunction Workshop on Process Analysis & Optimization 

8:30 a.m. - 5:00 p.m.
Fee: $595

Instructors: Professors from the Manufacturing Technologies Group at the University of Bologna, Italy

Learn how to optimize and analyze the aluminum extrusion process in this one-day intensive course from the experts at the Manufacturing Technologies Group at the University of Bologna in Italy. They have worked extensively with European extruders and die makers to optimize die design, improve welding phenomena in extrusion dies, increase die life, and analyze final microstructure of extruded profiles.

This course covers the following topics:

• Introduction to practical and analytical extrusion concepts
• Material flow and Friction in direct extrusion
• Die failure modes and die life prediction
• Seam welds, welding criteria and profile strength
• Charge welds and process performance
• Microstructure evolution and Streaks formation mechanisms.

About Prof. Lorenzo Donati
Lorenzo Donati is Associate Professor in Manufacturing Technologies in the “Department of  Engineering for Industry” in the School of Engineering (Forlì Campus) of Alma Mater Studiorum 
-University of Bologna. He received the Ph. D. in the course on “Engineering of manufacturing  systems, of metallurgy and applied measurements” of the Polytechnic University of Marche 
(Ancona, IT) with a dissertation on “Seam weld formation during aluminum extrusion: FEM  simulation and experimental verification of the mechanical and aesthetical proprieties”. The  research field concerns the analysis and optimization of forming processes with specific focus  on the extrusion of light alloy: seam and charge welds quality, die life estimation,  microstructure evolution during extrusion processing are some examples of the most relevant topics. He is organizer  and head of ICEB, the "International Conference on Extrusion and Benchmark", which is held in Europe every two  years since 2007. He coordinated and participated to several projects in the field of light alloys extrusion funded by 
International and National bodies as well as Companies.

A full list of publications is available at  http://www.unibo.it/docenti/l.donati 

George Oh & Judy Runge join Jason Weber of the AEC to discuss their upcoming Anodizing Essentials Workshop at this years ET'24 event in Orlando. For more details visit: ET In-Conjunction Workshops | Aluminum Extruders Council (aec.org)

8:30 a.m. - 5:00 p.m.
Fee: $495 AAC members / $895 nonmembers
Instructors: AAC member anodizing experts

Anodizing Essentials is part of the Aluminum Anodizers Council's (AAC) "School for Anodizers" that teaches more than the fundamentals of anodizing. This one-day class is designed to increase the knowledge and ability of anyone involved in operating an anodizing line. Anodizing Essentials Class details the foundation of quality anodizing, taking the learner through the entire process - beginning with the metallurgical properties of aluminum alloys commonly anodized through to the final rinse and sealing processes.

The program is designed to benefit anodizing production personnel at every level-from the line operator to the production manager, particularly if they are new to the business.
Workshop topics include:

• Anodizing Overview and Anodizing Video
• Metallurgy Basics for Aluminum Surfaces
• Racking
• Cleaning & Rinsing
• Etch, Desmut & Bright Dipping
• Anodizing Basics for Aluminum Surfaces
• Power - Rectifiers & Transformers for the Aluminum Surface Treatment Industry
• Dyeing & Electrolytic Coloring
• Sealing the Anodic Oxide

SHAPEMAKERS EPISODE 57

Welcome back to another riveting episode of SHAPEMAKERS, where we explore the fascinating world of shaping industries and innovations. In this special edition, Jason Weber, the VP of Operations and Government Affairs for the Aluminum Extruders Council (AEC), sits down with our distinguished guest ET'24 track chair, Gary Jones. 

Listen as they discuss the upcoming ET’24 Seminar, the 75th Anniversary of the AEC, and how to maximize your membership benefits by getting involved in AEC committees and groups. Also take a peak into which papers and tracks Bill is the most excited about in this years upcoming seminar. 

About The AEC:

Follow AEC on LinkedIn for the latest updates and industry insights.

• Stay informed about the Aluminum Extruders Council by visiting aec.org and following us on Twitter.

Stay Tuned for More SHAPEMAKERS: Don't miss out on future episodes of SHAPEMAKERS where we continue to explore the stories, innovations, and trends shaping industries worldwide. Subscribe on Apple Podcasts, Spotify, or your favorite podcast platform.

Thank you for joining us on this enlightening journey through the world of aluminum extrusion. Until next time, keep shaping the future!

SHAPEMAKERS EPISODE 56

Welcome back to another riveting episode of SHAPEMAKERS, where we explore the fascinating world of shaping industries and innovations. In this special edition, Jason Weber, the VP of Operations and Government Affairs for the Aluminum Extruders Council (AEC), sits down with our distinguished guest ET'24 track chair, Bill Rogers.

Listen as they discuss the upcoming ET’24 Seminar, the 75th Anniversary of the AEC, and how to maximize your membership benefits by getting involved in AEC committees and groups. Also take a peak into which papers and tracks Bill is the most excited about in this years upcoming seminar. 

About The AEC:

Follow AEC on LinkedIn for the latest updates and industry insights.

• Stay informed about the Aluminum Extruders Council by visiting aec.org and following us on Twitter.

Stay Tuned for More SHAPEMAKERS: Don't miss out on future episodes of SHAPEMAKERS where we continue to explore the stories, innovations, and trends shaping industries worldwide. Subscribe on Apple Podcasts, Spotify, or your favorite podcast platform.

Thank you for joining us on this enlightening journey through the world of aluminum extrusion. Until next time, keep shaping the future!

SHAPEMAKERS EPISODE 55

Welcome back to another riveting episode of SHAPEMAKERS, where we explore the fascinating world of shaping industries and innovations. In this special edition, Jason Weber, the VP of Operations and Government Affairs for the Aluminum Extruders Council (AEC), sits down with our distinguished guest ET'24 chairman, Jerome Fourmann.

Listen as they discuss the upcoming ET’24 Seminar, the 75th Anniversary of the AEC, and how to maximize your membership benefits by getting involved in AEC committees and groups.

About Jerome:

Jerome Fourmann, Global Technical Director and Casthouse Optimization at Rio Tinto - Aluminum, has been with the group for 15 years. His main duty is to support the company’s core value-added products' technical sales, of which they are the market leader.

Jerome is a passionate leader known for managing technical support activities in alloy selection, productivity enhancement, process improvement, training, troubleshooting, and industry standards development. Jerome drives growth through product development by identifying new market opportunities.

Titles: Technical Marketing | Metals & Minerals | Product Metallurgy & Market Development | Chairman of ET’24 | Accountable for developing value through a deep technical understanding of Metals & Minerals and market applications.

Connect with Jerome on Linkedin: Jerome Fourmann | LinkedIn

About Rio Tinto - Finding Better Ways to Provide the Materials the World Needs: #FindingBetterWays

We're finding better ways to provide the materials the world needs. Iron ore for steel. Low carbon aluminum for electric cars and smartphones. Copper for wind turbines, electric cars, and the pipes that bring water to our homes. Borates that help crops grow and titanium for paint.

Visit Rio Tinto's Website

About The AEC:

Follow AEC on LinkedIn for the latest updates and industry insights.

• Stay informed about the Aluminum Extruders Council by visiting aec.org and following us on Twitter.

Stay Tuned for More SHAPEMAKERS: Don't miss out on future episodes of SHAPEMAKERS where we continue to explore the stories, innovations, and trends shaping industries worldwide. Subscribe on Apple Podcasts, Spotify, or your favorite podcast platform.

Thank you for joining us on this enlightening journey through the world of aluminum extrusion. Until next time, keep shaping the future!

SHAPEMAKERS EPISODE 54 

Welcome back to another riveting episode of SHAPEMAKERS, where we explore the fascinating world of shaping industries and innovations. In this special edition, Jason Weber, the VP of Operations and Government Affairs for the Aluminum Extruders Council (AEC) sits down with our distinguished guest Brook Hamilton – President of Bonnell Aluminum.

Listen as they discuss the upcoming ET’24 Seminar, the 75th Anniversary of the AEC and how to maximize your membership benefits by getting involved in AEC committee’s and groups.

W. BROOK HAMILTON

PRESIDENT

Prior leadership and industry experience (both within the organization and prior) Brook started in the aluminum extrusion industry in 1983 with Alcan Extrusions in Toronto, Ontario in an inside sales / customer service role. He subsequently held roles in outside sales, production control (scheduling), production, and plant management in different locations across Canada. Later he became the general manager of an independent extruder in southwestern Ontario prior to joining Bonnell Canada in 2005 to run their stand-alone fabrication facility, Apollo. In 2006 he moved to Georgia to become plant manager of the Newnan facility and later became Business Development Manager in the corporate office. In 2013 he became the president of Bonnell Aluminum.

ABOUT BONNELL ALUMINUM

OVER 65 YEARS OF EXCELLENCE BEYOND EXTRUSION

For nearly seven decades, Bonnell Aluminum has pivoted, expanded, and connected our way to becoming an industry-wide innovator. Led by proprietary operations, like our fluid production processes, our tested and perfected procedures unlock the flexibility to meet the custom needs of any customer.

Those same customers have seen our role as extruder expand into that of a partner, deploying tailormade capabilities that can seamlessly move projects all the way from design to assembly to delivery with effortless efficiency. The Bonnell Aluminum of today embodies who we set out to be, while building on what we’ve learned along the way.

There is no shortage of companies offering extruded aluminum. But there’s only one that has proven Excellence Beyond Extrusion––Bonnell Aluminum.

https://bonnellaluminum.com/

About The AEC:

Follow AEC on LinkedIn for the latest updates and industry insights.

• Stay informed about the Aluminum Extruders Council by visiting aec.org and following us on Twitter.

Stay Tuned for More SHAPEMAKERS: Don't miss out on future episodes of SHAPEMAKERS where we continue to explore the stories, innovations, and trends shaping industries worldwide. Subscribe on Apple Podcasts, Spotify, or your favorite podcast platform.

Thank you for joining us on this enlightening journey through the world of aluminum extrusion. Until next time, keep shaping the future!

Welcome back to another riveting episode of SHAPEMAKERS, where we explore the fascinating world of shaping industries and innovations. In this special edition, we are honored to have Jason Weber, the VP of Operations and Government Affairs for the Aluminum Extruders Council (AEC), as our distinguished guest.

Episode Highlights:

1. Introduction to Jason Weber:
   • Dive into the professional journey of Jason Weber, unraveling his role as the VP of Operations and Government Affairs for the Aluminum Extruders Council.
2. Aluminum Extruders Council (AEC):
   • Gain insights into the pivotal work undertaken by the AEC, its mission, and the significance of aluminum extrusion in various industries at the upcoming ET’24 seminar.
3. ET'24 Seminar Preview:
   • Jason provides an exclusive sneak peek into the much-anticipated ET'24 Seminar, shedding light on the themes, speakers, and groundbreaking discussions expected at the event.
4. 75th AEC Anniversary Meetings:
   • Celebrate the rich history and accomplishments of the Aluminum Extruders Council as they gear up for their 75th Anniversary Meetings in March. Explore the milestones, challenges, and triumphs that have shaped the AEC over the years.

Follow AEC on LinkedIn for the latest updates and industry insights.

• Stay informed about the Aluminum Extruders Council by visiting aec.org and following us on Twitter.
•  

Stay Tuned for More SHAPEMAKERS: Don't miss out on future episodes of SHAPEMAKERS where we continue to explore the stories, innovations, and trends shaping industries worldwide. Subscribe on Apple Podcasts, Spotify, or your favorite podcast platform.

AEC Extrusion Kits: PSU Capstone Project Teams Interview

In 2023, AEC sponsored three capstone projects with the Pennsylvania State University engineering department. These projects are designed to develop aluminum extrusion kits for use by high school STEAM students, teachers and universities to support education in Science, Technology Engineering, the Arts and Math. Craig Werner, podcast host and AEC Workforce Development and Academic Engagement Team member), worked with Bonnell Aluminum, the supplier of the TSlots® extrusion components for the kits, Metal Exchange Corp./Pennex Aluminum, who hosted students at their Leetonia, Ohio extrusion facility, and Almag Aluminum, which has been part of this long-term development effort since inception.

Two projects were sponsored by AEC for the fall 2023 semester. Learn how well the concept connected with high school and university students and teachers, and how fun it was for all to use aluminum extrusions to support their education in this informative episode for AEC members, high school and university instructors, who may be interested in being a future “test site” for future extrusion kits.

Aluminum Safety Summit Preview

Nancy Klein, AEC Education Director, talks with Mel Mitchell, AEC Safety Team Leader, about the 2023 Aluminum Safety Summit, scheduled for November 8 & 9 in Rosemont, Illinois. Mel discusses the program highlights and the new program configuration. Learn what topics are on the schedule and who will be sharing their experience and knowledge at the Aluminum Safety Summit this year!

AEC Management Conference Preview: Heat Stress & Heat Illness with Dr. Thomas Bernard

Meet the Heat Stress and Heat Illness expert, Dr. Tom Bernard, professor at the University of South Florida College of Public Health.  Tom will preview his upcoming Safety Spotlight session on “Heat Stress and Heat Illness” in the AEC Management Conference General Session on September 20 in Chicago.  He will discuss the causes, research data, prevention and mitigation strategies that will educate extruders and suppliers on ways to keep plant workers cooler and safer.  Don’t miss this opportunity to chill with Dr. Tom Bernard in this hot topic episode!

Aluminum Extrusion Design Competition Winner Drew Klopfenstein

First-place winner in the 2023 Aluminum Extrusion Design Competition, Drew Klopfenstein from Purdue University, with AEC members Duncan Crowdis, Alexandria Industries, and Craig Werner, Werner Extrusion Solutions talk about Drew’s award-winning design. Duncan and Craig get into the details about the Design Competition and what the judges are looking for when evaluating the entries. They discuss Drew’s design of a modular aluminum extruded traffic light and his learning curve about the aluminum extrusion design process, his tips to other students on participating in the competition, including getting feedback from fellow design students to help improve the design, and more. For more information and to see Drew’s winning design, visit ETFdesign.org or AEC.org/DesignCompetition

How One Automotive Engineer Discovered the Value of ET

The ET Seminar is a technical conference that focuses entirely on the aluminum extrusion industry – from alloy development and process improvement to design and applications, and everything in between. Andrew Halonen, principal and engineer at Mayflower Consulting, had heard about ET for years but never thought it was an event meant for him–a design engineer who focuses on transportation lightweighting materials applications and integration, market research, technical business development and support. Hear about Andrew’s experience at ET in 2022 and decide for yourself if ET ’24, scheduled for April 30 – May 2, 2024 in Orlando, FL, is for you. Visit ET24.us for program and registration details.

Aluminum Extrusion Design Competition Winner Brady Hawks 

Brady Hawks, Second Place winner of the 2023 Aluminum Extrusion Design Competition and Industrial Design student at Purdue University in Indiana, talks with competition judge Craig Werner about his winning design. Brady discusses his electric motorcycle design, the inspiration for the design and how his background in the bicycle industry informed the design process, digging deep into research on the manufacturing process, alloys, design versatility and functionality that can be built in with extrusions, what he learned from participating in the competition, and more. Visit ETFdesign.org or AEC.org/DesignCompetition to see Brady’s award-winning design and learn how you can enter the competition for 2024! 

Challenges to Aluminum Extrusion for BEV Growth

Abey Abraham, principal of Ducker Carlisle and Mark Butterfield, president of manufacturing for Metal Exchange Corporation, the parent company of Pennex Aluminum, discuss the recent Ducker Research study that examines the use of aluminum extrusion in battery electric vehicles through the end of this decade. Challenges that need to be addressed, according to OEMs and Tier suppliers, to make the expected substantial BEV growth a potential reality – and the important role that extrusions may play are explored. Extrusion industry capacity, multi-material solutions, joining, sustainability and other issues are addressed in this noteworthy episode.

The past decade has seen doubling in per-vehicle aluminum extrusion use in North American passenger vehicles.  More recently, significant additional growth has emerged from aluminum extrusion’s role in battery electric vehicles (BEV) applications.  To better understand the likely future, AEC asked Ducker Research to examine the implications of the BEV market on extrusion use through the end of the decade. Abey Abraham, Principal at Ducker Carlisle, and Lynn Brown, Marketing Strategy Consultant for AEC, talk about the BEV market and aluminum extrusions.  They explore some key drivers, enablers and constraints for BEV demand as well as potential disruptors. In addition to discussing the future volume and market share of BEVs and hybrid electric vehicles, they explore the role of extrusions specific to BEVs, including battery boxes and battery protection/rockers.

Actions Designers and Specifiers Can Take to Reduce the Embodied Carbon in Aluminum Extrusion

Bonnell Aluminum’s Division Marketing Director, Guy Charpentier, and AEC’s Marketing Consultant, Lynn Brown, dig deeper into the 2022 update of AEC’s Environmental Product Declarations (EPDs). They revisit the major conclusions from a deeper analysis of the AEC EPDs and explore a subsequent sensitivity analysis that demonstrates the impact on embodied carbon that purchaser decisions can have. By adjusting certain “levers” in the sourcing of the raw material, specifiers, designers and architects can reduce the embodied carbon of their products by simply working with their aluminum extruder to meet their environmental impact goals. Learn how in this informative episode

Actions Designers and Specifiers Can Take to Reduce the Embodied Carbon in Aluminum Extrusion

Bonnell Aluminum’s Division Marketing Director, Guy Charpentier, and AEC’s Marketing Consultant, Lynn Brown, dig deeper into the 2022 update of AEC’s Environmental Product Declarations (EPDs). They revisit the major conclusions from a deeper analysis of the AEC EPDs and explore a subsequent sensitivity analysis that demonstrates the impact on embodied carbon that purchaser decisions can have. By adjusting certain “levers” in the sourcing of the raw material, specifiers, designers and architects can reduce the embodied carbon of their products by simply working with their aluminum extruder to meet their environmental impact goals. Learn how in this informative episode.

What are EPDs and What Do the Newly Released AEC EPDs Tell us?

Guy Charpentier, Chairman of the AEC Industry Promotion Steering Committee and Division Marketing Director for Bonnell Aluminum, talks with Lynn Brown, AEC’s Industry Promotion & Marketing Consultant, about Environmental Product Declarations (EPDs). They discuss what EPDs are, how they are developed and how they are used. They also review, in depth, the newly released aluminum extrusion industry average EPDs – one for mill finish, painted, or anodized aluminum extrusions and one for thermally improved anodized and painted aluminum extrusions. Listeners will get overview of the 2022 AEC EPDs, including four big takeaways that designers and specifiers should be aware of as they utilize aluminum extrusions..

Jeff Henderson, AEC President, and Robert DeFrancesco, AEC’s Fair Trade lead attorney, will discuss the latest developments in the Kingtom case. Specifically, they will examine the reversal of the Enforce and Protect Act (EAPA) decisions and the Withhold Release Order (WRO). Customs and Border Protection (CBP) implements Withhold Release Orders to prevent merchandise produced in whole or in part in a foreign country using forced labor from being imported into the United States. Learn more in this noteworthy episode.

The competition for today’s talent has never been more fierce. Young talent graduating and searching for a career are faced with a variety of options and most manufacturing companies are struggling to find ways to attract this needed talent to help them run and grow their business. The aluminum extrusion industry is no exception. Duncan Crowdis, leader of AEC’s Academic Engagement and New Talent Development Team and Shane Tredup of Custom Aluminum Products interview Savanah Kinney, a graduating engineering student with Illinois State University, to explore those seemingly elusive characteristics, both in the type of industry and the type of company, that attract today’s generation of students as they research options to start their career.

ET ‘22 will feature a Closing Keynote address by special guest, astronaut Mike Massimino. At ET Mike will talk about his experiences as an astronaut and fixing the Hubble Telescope. In this preview interview, Mike discussed his “stellar” career as well as his stint on the American television sitcom “The Big Bang Theory”.  Be sure to catch Mike Massimino in the Closing General session on Thursday, May 5 in Orlando, Florida!

AEC Die Clinic, one the Council’s most popular educational workshops, is being offered for the first time at ET – and is available to nonmembers of AEC. This program, which has trained hundreds of die professionals over the past 25+ years that the Die Clinic has been offered, provides those involved in extrusion die operations with a well-rounded education from experienced extruders and die makers who share their knowledge and expertise. AEC Die & Tooling Team Chair, Pawel Kazanowski of Hydro Aluminum Technology Center, talks with ET Seminar Committee Chair Craig Werner about what attendees can expect to learn from the AEC Die Clinic at ET and who should take advantage of this unique opportunity. 

Craig Werner, ET Seminar Committee Chairman talks with Lorenzo Donati, Associate Professor of Manufacturing Technologies in the Department of Engineering for Industry at the University of Bologna in Italy. Dr. Donati and his colleague, Dr. Barbara Reggiani, will be conducting their workshop during ET Week in Orlando, Florida, on Monday, May 2, 2022. Discover what you will learn in this course that covers practical and analytical concepts using finite element analysis to better understand the extrusion process and the principles discussed in the class. You’ll also hear a little more about Dr. Donati and his background in this engaging interview.

ET Chairman Craig Werner talks with Professor Wojtek Misiolek, Director of the Loewy Institute at Lehigh University, and top-rated instructor of AEC’s popular Extrusion Excellence Course. Learn about this one-day course, which will be offered two times at ET ’22, from the extrusion process expert who brings theory and practice together, providing a fundamental engineering approach to the aluminum extrusion process.

Duncan Crowdis and Craig Werner provide an overview of the Aluminum Extrusion Design Competition, the benefits for students and instructors and they talk with a student, Andrew Schoenjahn, from Grand Valley State University in Michigan, and leader of the GVSU Design Club.  Andrew shares his thoughts on how the Design Competition will help his fellow Design Club members in their future careers and how AEC’s resources have already given them a better understand of aluminum extrusions.

Olivier Gabis of Wagstaff, Inc., the Track Chair for the ET ’22 Billet Process Track, discusses the highlights of the BP Track with ET ’22 Chair Craig Werner. Safety, billet metallurgy, microstructure, impact of alloys on mechanical properties, new technologies, and more will be included in this essential track. Also, get a preview of all the options you can expect at ET by ET Vice Chair Jerome Fourmann.

Rob Nelson, Executive Vice President of Almag Aluminum and ET Value-Added Processes Track Chair talks with ET Seminar Committee Chair Craig Werner and Vice Chair Jerome Fourmann about some of the highlights of the papers in this track. From fabrication and finishing to machine learning and Industry 4.0, the Value Added Track covers a diverse set of subjects that will help extruders better understand and, therefore, improve processes and products

Hear what you can expect when attending the Management Issues (MI) Track at ET ’22 this May in Orlando, FL. ET Seminar Committee Chair Craig Werner and ET Vice Chair Jerome Fourmann talk with MI Track Chair Jason Weber, V.P. of Sales and Marketing at Taber Extrusions, who discusses the type of topics you can expect to hear and some of the highlights of the papers in this track. From automation and raw materials to safety and attracting and developing talent into the industry – the papers cover a variety of topics that would appeal to top management to better understand advancements and where the industry is headed for the future.

Learn more about the aluminum extrusion industry’s most important and anticipated technical conference at ET22.org.

ET ’22 Chairman Craig Werner and ET Vice Chair Jerome Fourmann discuss what to look forward to at ET ’22 this May in Orlando, FL. Frank Kraft, ET Extrusion/Die Theoretical (TH) Track Chair, talks about technical paper highlights in his track and discusses the importance of these theoretical papers—and how the concepts presented often become the technology of the not-too-distant future.  Jerome explains the elements of ET and how to save money when registering early and with a team.

Jeff Henderson, AEC President, and Greg Wittbecker, Senior Analyst with CRU North America, discuss China’s announcement to curtail production and the impact to aluminum extruders.  Greg also provides insight into the recent volatility in aluminum prices.

Craig and Jerome talk with Extrusion Equipment (EE) Track Chair Chip Edwards, who recently retired from Cardinal Aluminum. Chip reveals the interesting topics in the EE Track, how the information gathered at the EE Track sessions can help extrusion professionals improve their operations, the inner workings of being a Track Chair for ET, and why extrusion industry professionals need to attend ET ’22 next May.

ET ’22 Chairman Craig Werner and ET Vice Chair Jerome Fourmann talk with Mark Butterfield of Magnode – A Shape Corp. Company and ET Extrusion/Die Practical (EP) Track Chair. Mark shares his insights on one of the most popular tracks at ET, highlighting some topic trends, technical papers that stand out, and what delegates can expect to take away from attending the sessions in this track.

After being postponed – twice! – the Twelfth International Aluminum Extrusion Technology Seminar & Exposition—the biggest and best technical event for the aluminum extrusion industry—is finally back on track. ET staff members talk with Craig Werner, ET Seminar Committee Chair, and Jerome Fourmann, ET Seminar Committee Vice Chair, about what delegates can expect in May 2022 in Orlando, Florida, and why ET ’22 is a can’t-miss event.

Get a sneak peak of the AEC Press Maintenance Workshop scheduled for October 18-20, 2021 in Atlanta, from instructor Al Kennedy of Kennedy EuroTech. This workshop covers everything related to extrusion press maintenance and troubleshooting, equipment, press retrofit and more. Al explains who should attend and why, and he delves into what will be covered.

In this episode of Shapemakers, Jeff Henderson, the President of the Aluminum Extruders Council, discusses the Aluminum Safety Summit and its benefits to Members EHS teams, with access to a comprehensive, Safety-focused program designed for aluminum industry EHS professionals. Jeff will discuss the Summit with Chip Dollins of Service Center Metals, immediate-past Safety Team Leader at AEC, and with Curt Wells, Senior Regulatory Affairs Director at the Aluminum Association.

In this episode of The Shapemakers, Jeff Henderson, President of the Aluminum Extruders Council, will discuss how a National Apprenticeship Program can benefit AEC members and the industry.  Jeff will discuss this topic with Michael Todisco, President of Apprenticeship Connections.

The second podcast in this series is once again a discussion between long time industry players, Craig Werner of Werner Extrusion Solutions and Duncan Crowdis of Alexandria Industries, as they explore and describe the process that creates an aluminum extrusion by following the metal from a raw material to a finished aluminum extruded product.

In this episode of The Shapemakers, Jeff Henderson, the President of the Aluminum Extruders Council, will discuss how the AEC can use a Lobbying Firm based in Washington D.C. to advance our agenda in matters of trade, regulations, and promoting the use of aluminum extrusions.  Jeff will be joined by David Jory and Bob Emmett to discuss this important opportunity.

The first podcast in this series is a discussion between long time industry players Craig Werner of Werner Extrusion Solutions and Duncan Crowdis of Alexandria Industries. Hear about the benefits of using aluminum as a material in product design and the versatility and benefits of using aluminum extrusions as a solution to product design challenges.

Jeff Henderson, AEC President, Greg Wittbecker with CRU North America, discuss the current state of the aluminum market and the outlook for 2022.  This has been an unbelievable run for aluminum over these last few months.  Tune into this episode to get Greg’s views on the key drivers in today’s market and how the market will develop in 2022.

Jeff Henderson, AEC President, discusses the current state of the aluminum market and the outlook for 2022 with Rusal America’s President and CEO.  Tune into this episode to get Rusal’s views on the key drivers in today’s market and how the aluminum market may develop in 2022 in this timely interview.

Andrew Halonen of Mayflower Consulting talks with AEC Industry Promotion consultant Lynn Brown about aluminum extrusion use in cross-car beams, or instrument panel structures. Andrew discusses the key requirements for instrument panel structures, the various materials (including steel) that OEMs are using, how extrusions can be used in hybrid material solutions, and what other types of vehicles might benefit from extruded aluminum instrument panel beams.