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HOW IS CAST ALUMINUM PATIO FURNITURE MADE?

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Casting is the process by which a material is introduced into a mold while it is liquid, allowed to solidify inside the mold, and then removed, producing a fabricated object. Do you need an example? Jell-O, in effect, is cast into a mold while liquid, producing a wiggly-jiggly object your aunt with the purple hair can bring to Thanksgiving dinner. View Cast Aluminum Patio Furniture From Family Leisure Here.

Cast aluminum patio furniture (Grand Tuscany Dining by Hanamint is pictured right as an example) can be produced through either sand or die casting. Most cast aluminum furniture is sand-cast; not only is it cheaper to produce, it also makes for those delightful imperfections that add to the charm and authenticity of the pieces.

The first step in manufacturing cast aluminum is making a pattern, which is often carved in wood.

A molding box is prepared to receive the pattern. The bottom half of the box is packed with casting sand and the pattern is pressed into the sand. Additional sand is packed on top of the pattern and a lid is attached. The box is turned over, unlatched and the pattern is removed. The box is closed again, and the sand is allowed to dry; this forms the mold.

The box is then filled with molten aluminum alloy and is set aside until the metal is sufficiently cool to be strong. The sand is then removed, revealing a rough casted part. These are sanded, but cast parts will have many imperfections and rough edges, which gives the furniture its hand-crafted, traditional look. The San Marino Cast Aluminum Deep Seating Collection by Veranda Classics is pictured above left as an example.

Each piece of furniture is either welded or bolted together from the various cast parts; most high-end manufacturers of cast aluminum patio furniture smooth and sand the welds for a seamless look.

FUN FACT – The cap of the Washington Monument is cast aluminum.

HOW IS TUBULAR, EXTRUDED OR WROUGHT ALUMINUM FURNITURE MADE?

Wrought, extruded or tubular aluminum patio furniture is very popular because it requires no maintenance, is strong and durable, it won’t rust and it's generally moderately priced. This is the furniture you most often see at resorts and hotels, on cruise ships, beaches and poolside (the Baja Strap Collection from Woodard is pictured right as an example); while tubular patio furniture often has strap or sling seats, you can also find cushioned versions. View Wrought Aluminum Patio Furniture From Family Leisure Here.

The extrusion process is basically a simple one; the best visual of how it works is a Playdough Fun Factory. Just as you push the clay into the plastic “factory” a solid billet or bar of aluminum is pushed through a die. Push the clay through a star-shaped hole, you get a star-shaped tube; push it through a square shaped hole, you get a square shaped tube. The same is true of the aluminum; the billet will form the shape of the die.

High grade aluminum (the Belden Cushion Dining Collection from Woodard is picture left as an example) makes for the best tubing to use in furniture construction; also extrusions that include internal ribbing or reinforcements will result in the most durable, dent and bend-proof extrusions. Extrusions are welded and bolted together to form the final product.

Less common but still available is a rolled aluminum product. Rolled tubing is made by running a flat sheet of aluminum through a series of rollers which form it into a tube. A seam will run the length of the tubing, which makes it inherently weak and easily compromised. Folding “lawn” chairs are often made of rolled aluminum.

FUN FACT – Aluminum is the most abundant element in the earth’s crust!

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What is the best material for patio furniture? There is no correct answer, but when shopping for outdoor furniture, you will find many choices regarding the material used. While wood is always a perennial favorite, there are other materials that stand up a bit better to the weather conditions in Southern California. In this article we compare two of those: cast aluminum vs aluminum patio furniture.

What is Aluminum Patio Furniture?

These seating pieces and tables from Castelle are made from sturdy aluminum.

If you are looking for outdoor furniture that will not rust, aluminum is the preferred metal. When you see aluminum patio furniture on the market, it refers to an extruded material. Extrusion is simply taking a piece of aluminum and forcing it through a machine that shapes it into the desired shape (round or square). An advantage of aluminum patio furniture is that seating pieces can be stacked, making them easier to move around and store during the winter months.

Aluminum Quality Considerations

As with any type of outdoor furnishings, there are some things that affect the quality. For instance, the pieces should be heavy, which usually indicates better quality and a less likelihood that it will be blown over in a strong wind. The very nature of extruded aluminum means it is prone to denting and bending, although some outdoor furniture manufacturers add support within the framework to provide additional material strength.

Look for quality details, such as you will find in a Brown Jordan aluminum chair frame like this one.

Take a good look at the finish of the aluminum patio furniture you are considering. The pieces should be welded with a combination of aluminum, zinc and steel. Powder coating should be smooth and free of bubbles, blotches or stippling which can occur when the metal isn’t properly cleaned before application. Powder coated aluminum patio furniture is also preferred to spray painting, which makes the pieces susceptible to peeling and produces a finish that won’t last as long.

What is Cast Aluminum?

This cast aluminum lounger built for two is one of the signature pieces in the Florence collection by Gensun.

In considering cast aluminum vs aluminum patio furniture, the former is usually a better choice than the the latter. Cast aluminum is a solid material and outdoor furniture made from it typically uses a mold. It all starts with molten aluminum that is poured into a frame where it can set. This process allows for more intricate design details. It also makes cast aluminum patio furniture more stable and sturdier.

The company is the world’s best furniture casting part manufacturer supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

Will cast aluminum rust? That’s a question we get asked quite often and the answer is no. Unlike cast iron, cast aluminum patio furniture will not rust even if gets and stays wet for an extended period of time.

Cast Aluminum Quality Considerations

When shopping be aware that some cast aluminum patio furniture brands use fillers in the material. This produces a cheaper product that is less dense and more susceptible to breakage. Another aspect to consider is whether the manufacturer used 3D molds to form the pieces. If not, the backs of the furniture will be concave and unfinished. Finally, look at the welds. They should be sanded down and smoothed, but not to the point that it makes the junctions weak.

Gensun Casual makes some of the finest quality cast aluminum patio furniture on the market today.

Of all the cast aluminum patio furniture brands, Gensun Casual is one of the best quality furniture makers. You can see this illustrated in the image shown above but if you really want to see the quality difference firsthand, we invite you to visit one of our expansive showrooms so you can not only see, but feel, its superior design.

When it comes to cast aluminum vs aluminum patio furniture, there are advantages and disadvantages to both. Which you choose depends largely on your specific needs and sense of style.

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