The EASIEST and CHEAPEST way to build with aluminium extrusion - Acrobot

I used aluminium extrusion 2020 for the robot frame that I designed together with Basti Kuhz.

Picking the right connector is difficult, and you only realise the best choice after you've already made yours! Hopefully this video can help others make better decisions.

This is part of my Acrobot project, find more info about it here:
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[robertreynolds]

I've been using systems like this, Octonorm, MIS, GEM, and others like yours in the convention exhibit industry. My name is Bicycle Bob and I approved this message.

[geomcc]

Just started using T-slot extrusion this is fantastic stuff for building framing, desk's, Benches etc . wish I would of learned of this product sooner !!

[CoryMck]

You can buy 3 hole nuts and 2 hole nuts to make it easier to assemble.

End fasteners are very strong as long as you don't hand tighten them.

They make small wings that go around the extrusion and help it hold its position. 8020 calls them end fastener wings.

[tdumnxy]

Good video. I have never used aluminium extrusion so your demo of what is possible is very useful. If your Acrobot is still too heavy you might consider aluminium angle and flat bar which is a lot lighter still, held together with rivets (a hand riveting tool and rivets are super cheap). Also wire cross-bracing is super light but very strong if needed.

[Foche_T._Schitt]

The connectors are ridiculously over priced.

[TroyD-vobz]

I just wanted to add there are actually butterfly connectors for this purpose that distribute the force even better than just the bolt head. I totally agree that it's a great method (Although time-consuming to drill and tap) but Compared to traditional fasteners it's Considerably stronger and cheaper to put together. Again also more time-consuming. 8020 Actually sells a jig to drill the holes, Although you can use a self-centering downing jig.

[bobsamuel]

Daniel,
Good thinking, and creative ideas. Keep it up!

[hasserecht]

The connections also can twist since it only has one fixpoint. So depends on the application. Almost every Ender 3 style printer is assembled this way. All working fine since they don't bear much load .

[markusesslinger]

It is definitely a good connection — even more so when you add special pates that prevent twisting.
With double-wide profiles, you can do even better:
Use one hole in the way presented here, and a headless screw for the other. This prevents not only twisting, but also sliding.

[DeputatKaktus]

There is one other option, called Corner Cubes. They come in a 2D version for connecting two extrusions at a 90 degree angle, and a 3D version for connecting three extrusions. They are awesome. The only issue is: they are ridiculously expensive. You are looking at up to 4 or 5 Euros per piece. So not exactly budget friendly I’m afraid. But once you used them you won’t want anything else.

[Graham_Wideman]

Unlike when using brackets, when using the convenient joining method shown in the video, it's crucial to cut the extrusion ends perfectly square. That is the number one obstacle to this method. If anyone has seen an economical method to achieve square cuts, please respond to this comment. Aluminum extrusion can easily be cut on a bandsaw, tablesaw or chopsaw, but getting it extremely perpendicular in two axes is a challenge!

[WolfgangKislinger]

superbly implemented, not quite as relevant for a frame construction, but there would be a small metal plate (connector set) in between which makes the connection twist-proof as well

[EvilizedDead_EVL_DED]

Hey there super cool video! Any ideas on how to connect them parallel? I want to make a lattice ish thi g and wanted to connect them parallel. Much appreciated

[ahmedop]

thanks for the info man but I can't stop seeing Poppy from Trolls :D

[eveinah]

Hey! This video is very helpful! btw, did you use a 1 inch T-slot aluminum extrusion? If so, May I know what size of the cylinder head bolt are you using?

[arbjful]

For hanging applications such as window/door frames, a side plate connector would be better

[ulaB]

I do prefer item's Automatic-Fastening set. It's more flexible than having to drill a hole at an exact position and since you usually use two, the extrusion can't twist. But overall everything depends on what you want to build anyway.

[lookitsztral]

The company I work for sells Speed Locks, EVEN EASIER to use! No drilling involved. If you look up aluminum extrusion speed lock, you should be able to find a video I made or our websites :D

[hulkgqnissanpatrol]

I tried it and over time they backout just enough to cause a problem.
I ended up printing the corner pieces with PET and then screwed

[CloneBorg]

Very nice video, but if the aluminium rods are longer or the lever is larger, the screws may not hold. Additional brackets would have to be mounted here.