T-slot structural framing

T-slot structural framing is a framing system consisting of lengths of square or rectangular extruded aluminium, typically 6105-T5 aluminium alloy, with a T-slot down the centerline of one or more sides.

Examples of T-slotted profiles

1964 patent demonstrating early use of extruded T-slot members.

Cross-section of 80/20 T-slotted profiles, 10 and 15 series

A bicycle trailer for bike-trekking with three Euroboxes and aluminium profile framing

It is also known under several generic names, such as aluminium extrusion, aluminium profile and 2020 extrusion if the cross-section is 20x20 mm, alongside brand names, such as 80/20 framing.[1]

While the precise history of the T-slot framing system is not known, advancement in extrusion press technology in the early 1950s allowed for economic production of aluminium profiles,[2] and examples of use can be found from the early 1960s.[3]

Although no published standard defines the system, it is produced in a series of conventional sizes which allows for compatibility between manufacturers.

There is a variation on T-slot profiles known as V-slot rails where V-slot wheels are slotted into the V-shaped channels of the framing for linear motion in a 3D printer or other CNC machine.

Profiles

T-slot framing is divided into metric and fractional (imperial) categories. The T-slot is always centered along the long-axis of the piece. Pieces are available in each series with a square cross-section. Rectangular cross sections are also available which measure x by 2x (where x is the defined width) - e.g. 40mm by 80mm for 40 series.

Profile type	Profile name	Profile size
fractional	10 series	1"
fractional	15 series	1.5"
metric	20 series	20 mm
	25 series	25 mm
	30 series	30 mm
	40 series	40 mm
	45 series	45 mm

CAD model of a rotating T-slot nut used with aluminium T-slots/ T-track/ extrusions
T-nut (red) installed in a T-slot

Calculating load capacity and deflection

Formulas depend on the type of fastening of the aluminium profile:[4]

Simple supports

i.e. supported by swivel supports/joints at both sides:

Free support from both sides (e.g. swivel support (joint) from both sides)

\sigma ={\frac {F\times L}{4\times W}}\leq K

f={\frac {F\times L^{3}}{E\times I\times 48}}

Fixed supports

i.e. supported by rigid supports/joints at both sides:

Aluminium profile with fixed support from both sides (e.g. fixing to the wall from both sides)

\sigma ={\frac {F\times L}{8\times W}}\leq K

f={\frac {F\times L^{3}}{E\times I\times 192}}

Cantilever

i.e. supported by a rigid support/joint at one side:

\sigma ={\frac {F\times L}{W}}\leq K

f={\frac {F\times L^{3}}{E\times I\times 3}}

where:

${\textstyle \sigma [{\frac {N}{mm^{2}}}]}$ is the bending tension;
${\textstyle F[N]}$ is the force or load;
${\textstyle L[mm]}$ is the free profile length;
${\textstyle W[mm^{3}]}$ is the moment of resistance;
${\textstyle I[mm^{4}]}$ is the moment of inertia;
${\textstyle f[mm]}$ is the deflection;
${\textstyle E[{\frac {N}{mm^{2}}}]}$ is the elasticity module;
${\textstyle K[{\frac {N}{mm^{2}}}]}$ is the maximum bending tension.

Maximum bending tension
	Constant load	Pulsating load	Alternating load
$K[{\frac {N}{mm^{2}}}]$	100	40	30

References

"Find out About Our Mission and Vision Here at 80/20". 8020.net. Archived from the original on 2022-03-06. Retrieved 2022-05-15.
Bauser, M; Sauer, G; Siegert, K (2006). Extrusion (2 ed.). Materials Park, Ohio: ASM International. p. 6. ISBN 978-0-87170-837-3.
US patent US3143981A, Leslie E Tassell, "Demountable partition", published 1964-08-11, issued 1964-08-11, assigned to Tassell Hardware Co
"Aluminium profile load capacity | Blog - Tuli experience". www.tuli-shop.com. Retrieved 2023-09-26.

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[1] "Find out About Our Mission and Vision Here at 80/20". 8020.net. Archived from the original on 2022-03-06. Retrieved 2022-05-15.

[2] Bauser, M; Sauer, G; Siegert, K (2006). Extrusion (2 ed.). Materials Park, Ohio: ASM International. p. 6. ISBN 978-0-87170-837-3.

[3] US patent US3143981A, Leslie E Tassell, "Demountable partition", published 1964-08-11, issued 1964-08-11, assigned to Tassell Hardware Co

[4] "Aluminium profile load capacity | Blog - Tuli experience". www.tuli-shop.com. Retrieved 2023-09-26.