This paper deals with the design process of aluminium cross-sections with complex shapes in structural applications. The extrusion process of aluminium members enables for structural design a large variety of cross-section shapes. One of the main aspects of the design is the formulation of the initial concepts of the cross-sectional shape. So far, this shape has largely been determined by experience. Little research has been carried out on how to reach an initial cross-sectional shape. To improve the quality of the actual designs, more research must concentrate ont he conceptual phase. A case study is discussed to illustrate the theory presented in this paper.
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