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4040 aluminum extrusion, 6 mm slot (20-series, 2 × 2)

What are the exact dimensions of 4040 aluminum extrusion? · Hardware · basis: Misumi 5 series, 6 mm slot, from Misumi's dimensioned drawing of this profile; every slot, lip, cavity, bore and outline number is the drawing's

Exact dimensions. Every file is drawn at true size with no printing tolerance. The holes and pins that meet another part are listed below under Mating features, with the fit each joint needs; open those by your printer's or process's clearance before making the part. Mating features

width
40.0 mm
height
40.0 mm

Notes

  • 4040 aluminum extrusion, 6 mm slot (20-series, 2 × 2): 40 × 40 mm, 8 slots on a 20 mm pitch (Misumi 5 series, 6 mm slot). Source: Misumi's dimensioned drawing of this profile. Files: STEP and STL at 100, 1000 mm with square ends, and a DXF of the exact cross-section (mm), the master to extrude to any length. The section is centred on the origin and extruded along +Z from z = 0.
  • Slot: opening 6 mm, lip 2 mm thick at the opening, cavity 12 mm wide under the lips, 6 mm from the face to the cavity floor. Centre bore Ø4.2 mm per cell (the M5 tap drill).
  • Cavity side walls: the cavity is 12 mm wide under the lips, then follows the diagonal webs (1.5 mm thick, stated) down to the floor; the webs lie on the cell diagonals (45°), as drawn. The web thickness is stated on this series' 2060, 2080 and 4040 drawings.
  • The closed hollows between cells are drawn from the stated web (1.5 mm), core (8 mm square round each bore) and 2 mm face wall.
  • Outer corners R1 (stated).
  • Wrapping it: to make a part that fits around the bar, subtract the 1000 mm file (or extrude the DXF) from your solid; the outline is the drawing's 40 × 40 mm with no allowance, so open the pocket by your process's socket fit (see Mating features).
  • Attachments: the 20-series (6 mm slot) T-nuts, end caps, feet, brackets, gussets, plates and slot covers are cut from these same numbers; the fit check (tools/asm_extrusion_fit.py) placed each one on this profile with zero overlap.

Sizes

featuresizefrom
outline40 × 40 mm, R1 cornersdrawing
slot pitch20 mmdrawing
slot opening6 mmdrawing
lip thickness at the opening2 mmdrawing
cavity width under the lips12 mmdrawing
face to cavity floor6 mmdrawing
cavity depth under the lip (at the cavity wall)4 mmdrawing
core between opposite floors8 mmpitch − 2 × face-to-floor
diagonal web1.5 mmdrawing
centre boreØ4.2 mm × 4drawing
cross-section area472 mm²maker's page
mass1.28 kg/mmaker's page
Ix / Iy8.89 × 10⁴ / 8.89 × 10⁴ mm⁴maker's page
area of this model's section521.1 mm²computed from the DXF

Mating features

Drawn at the exact size. Open press, slide, run and socket features by your process's clearance; leave designed gaps and clamp fits as drawn.

featureexactmates withfitfiles
slot opening6T-nut tongue, slot-cover stem (20-series (6 mm slot))slideall
slot cavity12 wide under the lips, face to floor 6, lip 2T-nut body (slide-in, drop-in)slideall
centre boreØ4.2M5 thread (tap drill 4.2); end-cap pindesignedall
outline40 × 40, R1end-cap outline, foot socket, a pocket that wraps the barsocketall

Where the files are

Other publishers' files are linked, not hosted. "verify" = check the license at the link before commercial use.

Misumi40x40 Aluminum Extrusion - 5 Series, Base 20: product page with the cross-section drawing and section propertieswebMisumi site terms verify
Misumi4040 dimensioned cross-section drawingimageMisumi site terms verify

Free files

★ Free files 2 parts. Generated by Xem Studio from the standard; threads are plain cylinders at major diameter. CC BY 4.0. index.json

4040-20s-1004040 aluminum extrusion, 6 mm slot (20-series, 2 × 2): 40 × 40 mm section, 100 mm long, square ends; DXF = the exact cross-section in mmSTEP · STL · DXF
4040-20s-10004040 aluminum extrusion, 6 mm slot (20-series, 2 × 2): 40 × 40 mm section, 1000 mm long, square ends; DXF = the exact cross-section in mmSTEP · STL · DXF

Plain text: sheet.txt · JSON: /api/geometry?object=4040-aluminum-extrusion-20-series

4040 aluminum extrusion, 6 mm slot (20-series, 2 × 2), isometric render of a generated part
Render of 4040-20s-100 from the free STEP; not to scale.

How it fits

Parts that fit it

Slide-in T-nuts for 20, 30, 40, 45 mm and 1 in,…tongue in the opening, body in the cavity (slide)Drop-in T-nuts for 20, 30, 40, 45 mm and 1 in,…drops through the opening, turns 90° in the cavityL corner brackets for 20, 30, 40, 45 mm and 1 in,…legs flat on two profile faces at 90°Inside corner gussets for 20, 30, 40, 45 mm and 1…legs on two profile faces in the inside cornerSnap-in slot covers for 20, 30, 40, 45 mm and 1…stem in the slot opening, barb behind the lipsJoining plates, 2 × 3 holes, for 20, 30, 40, 45…holes over the slot centrelines on the profile pitchEnd caps for every T-slot profile hereend-cap-20-2x2: pins in the centre bores (press)

Alternatives

2020 aluminum extrusion, 6 mm slotsame 20-series (6 mm slot) slot, 20 × 20 mm2040 aluminum extrusion, 6 mm slotsame 20-series (6 mm slot) slot, 20 × 40 mm2060 aluminum extrusion, 6 mm slotsame 20-series (6 mm slot) slot, 20 × 60 mm

Also needed

Button head socket screws, M2–M8M5 screws through brackets into the T-nuts

You might also need

2080 aluminum extrusion, 6 mm slot (20-series), isometric render of a generated part
2080 aluminum extrusion, 6 mm slot (20-series)80.0×20.0 mm★ 2 files

Questions

What is the slot size of 4040 extrusion?

Opening 6 mm, lip 2 mm, cavity 12 mm wide under the lips and 6 mm deep from the face to the floor, per Misumi 5 series, 6 mm slot's drawing.

What T-nuts fit 4040 extrusion?

The 20-series (6 mm slot) nuts: slide-in (tnut-slide-20-m3, tnut-slide-20-m4, tnut-slide-20-m5) and drop-in versions, threaded M3, M4, M5 as tap-drill holes, cut to this slot's exact space.

Can I subtract this file to make a part that fits the extrusion exactly?

Yes: the outline is exactly 40 × 40 mm with R1 corners; extrude the DXF or subtract the 1000 mm STEP, then open the pocket by your fit.

How heavy is 4040 extrusion?

1.28 kg/m, 472 mm² section, as Misumi states. This model's section is larger because closed hollows / cavity details the drawing leaves undimensioned are drawn filled; use the stated weight, not the model's volume.

What in this model is not taken straight from the drawing?

The closed hollows between cells are drawn from the stated web (1.5 mm), core (8 mm square round each bore) and 2 mm face wall.