For manufacturers, flexibility and efficiency in design and production are non-negotiable. When developing automation equipment, ergonomic workstations, or custom guarding, you need solutions that reduce lead times, minimize costs, and scale with production demands. That’s where 80/20 aluminum t-slot extrusion stands out. Sometimes described as “aluminum lumber” or even an “erector set for adults,” 80/20 provides a versatile construction system that can be adapted to nearly any industrial environment.
Below, I’ll explore why OEMs are increasingly turning to 80/20, how it compares to traditional framing methods, and the real-world applications driving ROI.
Why OEMs Choose 80/20
Unlike welded steel, 80/20’s t-slot system offers a unique 2-degree drop lock feature that acts like a built-in lock washer once tightened. This not only improves structural integrity but also simplifies modifications.
Beyond the extrusion itself, OEMs benefit from:
- Design assistance – CAD support and layout help
- Custom machining – precision fabrication for unique needs
- Assembly services – prebuilt systems ready to deploy
- A massive parts library – brackets, hinges, handles, panels, casters, and more
For OEMs under pressure to innovate quickly, 80/20 allows engineering teams to outsource the framework design, build, or kitting, freeing up valuable time to focus on core product development.
Advantages of 80/20
Speed and Scalability
Once a prototype is validated, OEMs can replicate designs with consistency and speed. Compared to steel fabrication, 80/20 shortens the path from concept to production while reducing both labor and material costs.
Flexibility Past the First Project
Engineers who use 80/20 for one application quickly discover dozens of additional uses—machine frames, conveyors, automation platforms, and even ergonomic operator stations.
Durability and Strength
Despite being aluminum, 80/20 is comparable in strength to A36 carbon steel and offers tools like a deflection calculator to verify load capacity for automation and heavy-duty equipment bases.
Common OEM Applications
1. Machine Frames & Guarding
Machine builders often start with 80/20 for safety enclosures and equipment frames. The modularity allows engineers to incorporate sensors, interlocks, light curtains, and access panels directly into the frame—while retaining the ability to repurpose or expand later.
Design tip: If you’re new to 80/20, start with simple layouts. As you become familiar with the available fasteners and components, your builds will speed up significantly.
2. Operator Workstations & Interfaces
Workstations are one of the most popular OEM use cases. Designs can be replicated across facilities or easily modified for operator-specific ergonomics.
Real-world example: A manufacturer running three shifts built fully adjustable stations to accommodate operators ranging from 4’2” to 6’3”. With 80/20, height adjustments and reconfigurations were built directly into the design—supporting both operator safety and productivity.
3. Test Fixtures & Assembly Jigs
For R&D and QA teams, 80/20 enables rapid prototyping. Fixtures can be reconfigured on the fly, reducing the cost of iteration and shortening the timeline to validation.
Adjustable assembly jigs also save space: instead of maintaining multiple stations for different operators or product variations, one flexible fixture can serve all needs.
4. Automation & Equipment Bases
Contrary to the misconception that aluminum can’t handle heavy-duty automation, 80/20 supports robotics, conveyors, and pneumatic systems reliably.
Applications include:
- Robot pedestals with adjustable mounting
- Conveyor supports integrated into line layouts
- End-of-arm tooling frames that can be quickly reconfigured for new parts
This adaptability makes 80/20 a natural partner in automation and smart manufacturing environments. You can build smarter, faster with 80/20.
A Real-World Case Study
A manufacturer GCG worked with needed to integrate a robot into a production cell while maintaining worker safety and minimizing downtime.
- Challenge: The system required quick-change end-of-arm tooling and safe part transport.
- Solution: Engineers used 80/20 to create modular tooling mounts and a material handling cart that safely moved parts outside the robot cell.
- Result: Production ramped up with fewer delays, faster changeovers, and improved throughput per line.
Integration with Other Technologies
Mounting HMIs, monitors, sensors, and keyboards onto 80/20 systems is straightforward with prefabricated arms, brackets, and monitor mounts—or with fully custom designs. Engineers typically need little more than a set of T-handles to assemble most structures.
Cost & Efficiency Gains
80/20 reduces waste by enabling modifications without scrapping material. OEMs also leverage kitting services, which allow preconfigured assemblies to be stocked, modified, and deployed quickly reducing lead time and labor requirements while accelerating time-to-market.
Download this brochure to learn more about the benefits
Tips for OEMs Getting Started
- Work with a distributor partner like GCG: Local distributors can provide design support, machining, and assembly—helping you avoid the learning curve.
- Leverage design tools: 80/20’s AutoQuoter X CAD plugin accelerates design and quoting.
- Start simple: Build familiarity with the system before tackling highly complex projects.
Why Make 80/20 a Standard?
As factories accelerate automation adoption, engineers need solutions that scale. 80/20 offers:
- Repeatable designs that transition easily from prototype to production
- Turnkey solutions delivered fully assembled and floor-ready
- Versatility across guarding, displays, workstations, and automation equipment
Once used mainly for guarding, 80/20 is now a staple in automation, ergonomic design, and smart manufacturing. OEMs who standardize on 80/20 gain a platform for continuous improvement—reducing costs, improving safety, and future-proofing their operations.
Takeaway: For OEM engineers, 80/20 is not just an extrusion system—it’s a design and manufacturing toolkit that accelerates innovation while keeping costs in check.
As a long-standing, nationally recognized 80/20 distributor, GCG brings over 30 years of expertise supporting manufacturers across 17 states. Our team of highly skilled engineers is dedicated to helping you improve productivity and achieve rapid ROI through smarter automation strategies. Backed by deep product knowledge and real-world experience, we provide tailored support for 80/20's full range of t-slot aluminum systems. Learn more about our capabilities.
