The lightest premium machined material. So it allows designers to make a product larger, more sculpted, or more functional without it feeling like a brick.
Density: 6061-T6 at about 2.70 g/cc density. 7075-T6 is about 2.81 g/cc density.
Grades: 6061-T6 is the default aluminum. It is a heat-treated magnesium-silicon alloy. 7075-T6 is the premium/high-strength aluminum-zinc alloy that is harder to work with but more corrosion-resistant. 1100 is pure aluminum. 3003/5052 are magnesium/manganese alloys which are less ideal than 6061/7075 for precision machined objects.
Finishes: raw machined, bead blasted, brushed/satin, tumbled, polished, clear anodized, color anodized, hardcoat anodized / Type III, laser engraved, Cerakote-coated, and powder coated. Anodizing is arguably the most important finish. Type II anodizing is common for colored consumer products; Type III hardcoat anodizing produces a thicker, more wear-resistant surface and is common on flashlights, tools, and hard-use EDC.
Common Objects: flashlights, camera bodies, audio hardware, luggage, machined wallets, pens, key organizers, carabiners, desk objects, rulers, knobs, handles, cases, keyboard bodies, coffee tools, and small home/desk hardware.
Cons: It weighs less-which means it can feel less premium than heavier metals. Cheap anodized aluminum-IFYKYK. Edges can dent, threads can strip, corners can show silver wear through colored anodizing, and raw aluminum scratches easily.
Comparisons: Compared w/ titanium, aluminum is lighter, cheaper, easier to machine, and better for colorful anodizing, but it is softer, less premium, easier to dent, and less durable in threads or high-wear mechanisms. Compared w/ stainless steel, aluminum is much lighter and easier to machine, but steel feels denser, more durable, and more luxurious in a “cold hard object” way. Compared w/ brass/copper, aluminum is far lighter and cleaner, but it lacks patina, warmth, and density. Compared w/ tungsten, aluminum is the opposite: light and practical rather than heavy and jewel-like. Compared w/ zirconium, aluminum is much cheaper and more manufacturable, but far less exotic.
Buyer facing labels should mention: 6061-T6 aluminum, 7075-T6 aluminum, hardcoat anodized aluminum, bead-blasted aluminum, clear anodized aluminum, black Type III anodized, or aircraft-grade aluminum.
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