When it comes to plantation shutters, durability isn’t just a bonus — it’s essential. At DIY EasyFit Shutters, one of the key features that sets our shutters apart is the aluminium-reinforced core inside every stile and blade. But have you ever wondered how that aluminium core is actually made?

Today, we’re taking you behind the scenes into the world of aluminium engineering — and why this innovation makes our shutters some of the strongest and most reliable in Australia.

Why Aluminium? Strength, Stability & Long-Term Performance

Before we dive into the manufacturing process, it’s important to understand why aluminium is the material of choice.

Aluminium is:

Lightweight yet incredibly strong
Resistant to corrosion and humidity — perfect for coastal areas like Gold Coast & Tweed
Thermally stable, helping shutters maintain their shape
Ideal for reinforcement without adding heavy weight

This is why aluminium is used in aerospace, construction — and in the internal structure of our premium shutters.

How Aluminium Cores Are Made: Step-by-Step

1. High-Grade Aluminium Selection

Everything begins with premium-grade aluminium, chosen for its purity and strength. Only the highest-quality material is approved to ensure consistent performance.

2. Melting & Purification

The aluminium is heated until molten, then goes through a purification process to remove impurities.
This step ensures:

Uniform strength
Smooth structure
Long-term durability

3. Extrusion Into Reinforcement Profiles

This is where engineering meets precision.

The molten aluminium is pushed through a precision die, creating long, perfectly shaped profiles designed to fit inside shutter blades and stiles.

Extrusion ensures:

Exact dimensions
Even thickness
Smooth internal structure

4. Cooling & Hardening

The profiles are rapidly cooled to lock in their strength. This increases rigidity and prevents warping — crucial for shutters installed in humid areas like Gold Coast, Northern NSW, and Sydney.

5. Cutting Into Custom Lengths

Once hardened, each aluminium core is cut to exact lengths depending on your custom shutter order.

This allows the reinforcement to integrate perfectly into every stile and blade.

6. Insertion Into Shutter Components

During shutter assembly, the aluminium cores are installed inside the components before final finishing.
This internal reinforcement provides:

Superior stability
Protection against warping
Increased impact resistance
Longer lifespan

Many DIY shutter companies do not use aluminium reinforcement at all — one of the biggest differences in quality, longevity, and value.

What This Means for Your Shutters

With aluminium reinforcement, your shutters stay:

✔ Straight
✔ Strong
✔ Smooth to operate
✔ Beautiful for decades

They’re engineered for Australian homes, especially in humid, coastal, and high-heat regions.

Our Quality Promise

At DIY EasyFit Shutters, every panel is built with:

✨ Aluminium-reinforced stiles & blades
✨ VOC-free, water-based paint
✨ 25-year warranty (terms & conditions apply)
✨ Durability designed for QLD and NSW climates

We spare no expense because your shutters should last decades — not just a few years

Related Blogs You May Like

If you enjoyed this behind-the-scenes look, here are more helpful reads:

🔗 How Plantation Shutters Are Made: From Raw Material to Your Window
A full breakdown of the entire shutter manufacturing process.

🔗 DIY Shutters vs Other Brands: What Makes EasyFit Different?
A comparison of build quality, reinforcements, warranty, and materials.

🔗 How Louvre Blades Work: Light, Privacy & Airflow Explained
A simple guide to how louvre shutters control your indoor environment.

🔗 Why Aluminium-Reinforced Shutters Are Essential in Queensland & NSW Homes
Especially for homes in humid or coastal areas.

🔗 Maximising Natural Light with Plantation Shutters
Tips on brightening your home using adjustable louvres.