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How to Produce a Therm-Breaking Aluminum Profile

Aluminum is a highly thermal conductive material that will rapidly transfer exterior climatic temperature unless something is done to stop the thermal conduction. A thermal barrier system will improve thermal performance while maintaining the structural and long-term durability of the fenestration unit. According to the thermal strut manufacturer, aluminum is 533 times more conductive than polymide insulating strips.

Normally, there are three steps in the process of therm-breaking aluminium profiles.


The aluminum profile is extruded with a strategically placed channel to encapsulate an insulating polymer. The channel surface is conditioned with special equipment to create a "mechanical lock".


A two-part polymer is dispensed into the channel as a liquid, then hardens into a strong, structural insulating element.

The metal "bridge" is mechanically removed from the bottom of the channel, eliminating the conductive aluminum element and producing a non-metal-to-metal thermal barrier.
With thermal strut, products can be manufactured with two-tone finishes; because interior and exterior components can be coated before assembly. Architects and designers can choose to apply the interior and exterior finishes that best match their cost, performance and design requirements.

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