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.
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:
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.
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.
Engineers who use 80/20 for one application quickly discover dozens of additional uses—machine frames, conveyors, automation platforms, and even ergonomic operator stations.
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.
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.
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.
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.
Contrary to the misconception that aluminum can’t handle heavy-duty automation, 80/20 supports robotics, conveyors, and pneumatic systems reliably.
Applications include:
This adaptability makes 80/20 a natural partner in automation and smart manufacturing environments. You can build smarter, faster with 80/20.
A manufacturer GCG worked with needed to integrate a robot into a production cell while maintaining worker safety and minimizing downtime.
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.
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.
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As factories accelerate automation adoption, engineers need solutions that scale. 80/20 offers:
Oce 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.