Hydro metal Factory provides its clients with the best foam-injected aluminum profiles in Egypt. These profiles are injected with a foaming material, usually polyurethane, inside their internal cavity to achieve superior thermal and sound insulation while maintaining the strength of aluminum. The profiles are engineered with an internal channel through which polyurethane foam is injected at a specific density to enhance insulation and reinforcement properties without affecting the shape or weight.

Components of Foam-Injected Aluminum Profiles

These aluminum profiles are designed for use in applications such as exterior doors, insulated windows, garage doors, and wall cladding systems. They consist of:

• Aluminum Frame: Typically made from alloy 6061 and extruded into specific shapes based on its intended use. It includes one or more closed internal cavities and may have multiple chambers for enhanced thermal performance. Its role is to provide structural support, define the exterior design, and securely hold glass panels, inserts, or accessories.
• Foam Material: Made of polyurethane, with a density of up to 60 kg/m³ (adjustable based on application). It expands after injection to fill the cavity completely, providing excellent thermal and acoustic insulation and increasing overall profile strength and energy efficiency.
• Side Covers or Sealing Strips: Used to tightly seal the ends of the profile before or after foam injection, preventing leakage and ensuring even foam distribution.
• Insulation Strips or Rubber Gaskets: Installed along the edges, especially in window or door applications, to provide additional sealing against water, dust, and noise.
• Coatings and Finishing Layers: These include anodizing for improved corrosion resistance, powder coating in various colors, or wood grain laminate to match different design styles.
• Mounting and Assembly Accessories: A set of hinges, handles, screws, and fasteners tailored to the specific application (doors, windows, etc.).

Advantages of Foam-Injected Aluminum Profiles

Foam-injected aluminum profiles are among the best solutions for doors, windows, and architectural or industrial gates. They combine metallic strength with effective insulation, making them a preferred choice in residential, commercial, and industrial buildings.

• The injected foam acts as a highly efficient barrier against heat transfer, reducing the ingress of external heat, lowering cooling and heating costs, and maintaining stable indoor temperatures. Hence, they are widely used in hot or cold climates.
• The internal foam significantly reduces external noise—by up to 60%—making them ideal for homes near roads, factories, or high-traffic areas.
• The foam is moisture-resistant and non-corrosive, preventing leaks and degradation over time. This makes the profiles suitable for exterior facades and doors exposed to harsh weather conditions.
• These profiles offer excellent structural strength as the foam reinforces the internal body, helping prevent unexpected dents or vibrations.
• They can be painted or finished in various textures and colors, presenting a sleek modern look. Notably, they are corrosion- and peel-resistant—unlike wood or steel—and thus can last for many years without performance or aesthetic degradation.