Aluminum groove profile - Overview and calculation of deflection

Aluminum construction profiles and system profiles act as load-bearing frame profile in mechanical and process engineering. Together with the respective attachments, the aluminum profile forms a stable and lightweight structure for housings and structural and functional tasks. This article will give you an overview of MISUMI - aluminum construction profiles available in Europe and how you can calculate their deflection depending on the load case.

Aluminum Profile Use Cases

Aluminum groove profiles are very stable and, due to their low weight, are well suited for lightweight construction. The anodizing or baked paint protects them from environmental influences. Due to their matched modular design they can be used in numerous applications. Standardized dimensions and groove widths allow common aluminum profiles to be joined in a variety of ways. Connecting elements / profile connectors and other accessories are available for this purpose.

In many machines and systems, the aluminum profiles are not only used for enclosures. Aluminum profiles often form the structural skeleton of a machine or application. The modular system profiles are also used to accommodate applications or devices. In addition, aluminum profiles are increasingly integral to assembly lines, test stations, workstations and material flow systems in industrial manufacturing. Thanks to standardization, aluminum profiles offer a high degree of flexibility for short-term adaptations and expansions of existing designs. Custom solutions can be realized with a wide selection of profile cross sections and groove widths. These range from simple carrier frames to complex multi-axis systems in manufacturing and automation technology. In electrical engineering and sensor technology, aluminum profiles are also used as cable routing or carrier systems for light barriers, scanners and cameras. This allows for a clean, safe and easy-to-maintain installation.

As a support structure for profile rail guides, aluminum profiles serve as a reliable mounting option for the guide elements. Profile rails are generally integrated directly into or threaded onto the T-slot profiles. For some examples, see our article Linear Systems - Stability and precision by combining linear units with linear guides.

A major advantage of aluminum profiles is their reusability. For conversions or decommissioning, the assembled components can usually be disassembled and reassembled without residue.

Aluminum profile overview

MISUMI aluminum construction profiles are classified by series. The different series describe the thread size of the T-slot nut for the respective series. A Series 6 system profile is designed for slot nuts with an M6 thread and has a groove width of 8 mm

The part number consists of the basic information of the respective profile, as shown here in the example:

HFS5-2020

describes a:

  • configurable profile
  • Series 5
  • with dimensions 20 x 20 mm

KHFS5-2020-1000

describes a:

  • fixed-length profile (1000 mm)
  • Series 5
  • with dimensions 20 x 20 mm

If the part number is preceded by a K, these are precut profiles with a fixed length.

Square Series 3 aluminum profile (HFS3 / KHFS3)
Square Series 3 aluminum profile (HFS3 / KHFS3)

The standard profiles are square and have a groove on each side. MISUMI also offers profiles that only have a groove on two sides. The closed grooves act as an outer edge to create a uniform appearance. Thus, no grooves are visible on the outer edges. The profile versions also differ from each other by the versions standard, light (hollow), and high rigidity (solid), not all of which are offered on the European market. With an edge dimension of 15x15mm, the Series 3 is the most compact profile rail series offered by MISUMI in Europe. Only a limited range of connectors and accessories are available for this series.

A small selection of the standard dimensional aluminum construction profiles available from MISUMI in Europe can be found in the following overview:

EU overview of MISUMI alu profiles - Material: EN AC51400-T5 equiv. (as of 04/2025)
Line Slot Image Dimensions Part Number LINK Length (mm) Finish
Line 5 20 x 20 HFS5-2020 View item Configurable * ∙Nat. anodized
20 x 40 HFS5-2040 View item Configurable * ∙Nat. anodized
40 x 40 HFS5-4040 View item Configurable * ∙Nat. anodized
20 x 20 KHFS5-2020-1000 View item 1000 ∙Nat. anodized
20 x 20 KHFS5-2020-4000 View item 4000 ∙Nat. anodized
20 x 40 KHFS5-2040-1000 View item 1000 ∙Nat. anodized
20 x 40 KHFS5-2040-4000 View item 4000 ∙Nat. anodized
40 x 40 KHFS5-4040-4000 View item 4000 ∙Nat. anodized
20 x 20 KHFSB5-2020-4000 View item 4000 '∙Black anodized
20 x 40 KHFSB5-2040-4000 View item 4000 '∙Black anodized
Line 6 30 x 30 HFS6-3030 View item Configurable * ∙Nat. anodized
30 x 60 HFS6-3060 View item Configurable * ∙Nat. anodized
30 x 90 HFS6-3090 View item Configurable * ∙Nat. anodized
60 x 60 HFS6-6060 View item Configurable * ∙Nat. anodized
30 x 30 HFSB6-3030 View item Configurable * '∙Black anodized
30 x 60 HFSB6-3060 View item Configurable * '∙Black anodized
30 x 30 KHFS6-3030-1000 View item 1000 ∙Nat. anodized
30 x 30 KHFS6-3030-4000 View item 4000 ∙Nat. anodized
30 x 60 KHFS6-3060-1000 View item 1000 ∙Nat. anodized
30 x 60 KHFS6-3060-4000 View item 4000 ∙Nat. anodized
30 x 90 KHFS6-3090-4000 View item 4000 ∙Nat. anodized
60 x 60 KHFS6-6060-4000 View item 4000 ∙Nat. anodized
30 x 30 KHFSB6-3030-4000 View item 4000 '∙Black anodized
30 x 60 KHFSB6-3060-4000 View item 4000 '∙Black anodized
Line 8 40 x 40 HFS8-4040 View item Configurable * ∙Nat. anodized
40 x 80 HFS8-4080 View item Configurable * ∙Nat. anodized
40 x 160 HFS8-40160 View item Configurable * ∙Nat. anodized
45 x 45 HFS8-4545 View item Configurable * ∙Nat. anodized
45 x 90 HFS8-4590 View item Configurable * ∙Nat. anodized
50 x 50 HFS8-5050 View item Configurable * ∙Nat. anodized
60 x 60 HFS8-6060 View item Configurable * ∙Nat. anodized
80 x 80 HFS8-8080 View item Configurable * ∙Nat. anodized
90 x 90 HFS8-9090 View item Configurable * ∙Nat. anodized
40 x 40 HFSB8-4040 View item Configurable * '∙Black anodized
45 x 45 HFSB8-4545 View item Configurable * '∙Black anodized
80 x 80 HFSB8-8080 View item Configurable * '∙Black anodized
40 x 40 HFSF8-4040 View item Configurable * ∙Nat. anodized
40 x 80 HFSH8-4080 View item Configurable * ∙Nat. anodized
18 x 30 HFSPURE8-1830 View item Custom (50 to 3000 mm) ∙Nat. anodized
40 x 40 HFST8-4040 View item Configurable * ∙Nat. anodized
40 x 160 KHFS8-40160-4000 View item 4000 ∙Nat. anodized
40 x 40 KHFS8-4040-1000 View item 1000 ∙Nat. anodized
40 x 40 KHFS8-4040-4000 View item 4000 ∙Nat. anodized
40 x 80 KHFS8-4080-1000 View item 1000 ∙Nat. anodized
40 x 80 KHFS8-4080-4000 View item 4000 ∙Nat. anodized
45 x 45 KHFS8-4545-1000 View item 1000 ∙Nat. anodized
45 x 45 KHFS8-4545-4000 View item 4000 ∙Nat. anodized
45 x 90 KHFS8-4590-4000 View item 4000 ∙Nat. anodized
50 x 50 KHFS8-5050-4000 View item 4000 ∙Nat. anodized
60 x 60 KHFS8-6060-4000 View item 4000 ∙Nat. anodized
80 x 80 KHFS8-8080-4000 View item 4000 ∙Nat. anodized
90 x 90 KHFS8-9090-4000 View item 4000 ∙Nat. anodized
40 x 40 KHFSB8-4040-4000 View item 4000 '∙Black anodized
45 x 45 KHFSB8-4545-4000 View item 4000 '∙Black anodized
40 x 80 KHFSB8-8080-4000 View item 4000 '∙Black anodized
40 x 40 KHFSF8-4040-4000 View item 4000 ∙Nat. anodized
40 x 80 KHFSH8-4080-4000 View item 4000 ∙Nat. anodized
40 x 40 KHFST8-4040-4000 View item 4000 ∙Nat. anodized
Add-ons: Brackets/connectors, T-nuts, end caps, slot covers, handles, hinges, latches & stops, casters, base plates, etc.
Note: * 50 to 4000 mm (0.5-mm steps)

Special shapes for aluminum profiles

Classic special shapes deviating from the square cross-section are rectangular profiles such as the profile HFS8-4080, which have two grooves on the long side.

However, there are also other dimensions such as the profile EFSP6-30030, which has an edge length of 30 x 300 mm and provides 10 grooves on the side, triangular profiles such as the profile HFS45TR6 or angle profiles with choice of angles of 30°, 45° or 60° such as the profile HFS60A5 with a 60° angle.

Another special shape comes as profiles that are L-shaped and form a closed and rounded profile edge to create soft edges in constructions. The HFSR5 profile is such a Series 5 profile, for example. But special profiles, which are hollow inside and have a large cross-section, also expand the design options.

The different shapes can also be combined with each other, allowing users to select the profile that suits different tasks. In regions that are not heavily loaded, a smaller profile may then be used to reduce weight. This modularity enables lower inertia to be achieved even with moving applications. Aluminum profile joints between different profile sizes such as Series 6 and Series 8 are also possible. For this purpose, special connectors are available, which can connect different groove widths together. Depending on the manufacturer, the profile dimensions, such as the groove depth, may vary for profiles. Therefore, the groove dimension must be taken into account when selecting the slot nut or hammer nut.

Plastic covers and profiles bent with a selectable radius, such as the HFSMG5 profile, can be used to create curved and rounded protective edges on necessary enclosures or guards. These can provide additional protection for frame constructions.

Beveled aluminum profile
Beveled aluminum profile
Curved aluminum construction profile
Curved aluminum construction profile

Calculation of deflection

The required load capacity of aluminum profiles depends on the intended use and load case. For example, if the application is a boom clamped on one side with a vertical point load, or a uniformly distributed load, or an aluminum profile clamped on both sides? And which profile is used?

The following values are required to calculate the deflection f in mm:

  • F = load in N
  • L = free profile length in mm
  • I = moment of inertia in mm4
  • E = modulus of elasticity of the material in N/mm2, typically 70,000 N/mm2 for aluminum

This results in the following steps for calculating the deflection:

1. Determine the force F acting on the profile or the line load q.
2. Measure the free length L of the aluminum profile between the supports.
3. Determine the moment of inertia I (depending on the profile cross-section) from data sheets.
4. Calculate the deflection.

The formula varies depending on the load case. For a cantilever clamped on one side, the maximum deflection at the free end would be calculated, for example, as follows:

f = \frac{F \times L^{3}}{3 \times E \times I}

The deflection of T-profiles is in principle calculated according to the same physical principles. However, it should be noted that the moment of inertia I is distributed differently due to the geometry. Lateral deflections and torsion can therefore occur with one-sided loads. The distance to the neutral line (imaginary line in the beam cross-section that is neither compressed nor stretched during bending, i.e. remains stress-free) becomes relevant for the calculation. This is usually in the center of the cross section, but shifts for asymmetrical profiles such as T-profiles or T-slot profiles.

Example: aluminum profile with point load at the free end
Example: aluminum profile with point load at the free end
Example: cantilever aluminum profile
Example: cantilever aluminum profile
Example: cantilever aluminum profile - uniformly distributed load
Example: cantilever aluminum profile - uniformly distributed load

The following table provides a brief overview of the recommended load capacity of MISUMI aluminum construction profiles:

MISUMI alu profiles - Load guideline - Material: EN AC51400-T5 equiv.
Part number Height x Width Section
modulus x 103 (mm3)		 Area moment
of inertia
x 104 (mm4)		 Allowable load* (N)
Type   For profile length
500 mm		 For profile length
1000 mm
HFS 5 2020 20 x 20 0.74 0.74 99 24
2040 20 x 40 1.35 1.35 182 45
40 x 20 2.55 5.11 687 171
4040 40 x 40 4.45 8.9 1196 299
HFS 6 3030 30 x 30 1.89 2.83 381 95
3060 30 x 60 3.55 5.33 716 179
60 x 30 6.84 20.53 2758 689
3090 30 x 90 5.62 8.43 1133 283
90 x 30 14.71 66.19 8892 2223
6060 60 x 60 13.78 41.35 5555 1388
HFS 8 4040 40 x 40 5.24 10.48 1407 351
4080 40 x 80 9.95 19.91 2674 668
80 x 40 18.07 72.26 9707 2426
40160 40 x 160 19.36 38.72 5201 1300
160 x 40 61.89 496.3 66676 16669
4545 45 x 45 6.77 15.25 2048 512
4590 45 x 90 14.44 32.5 4366 1091
90 x 45 27.9 125.5 16860 4215
5050 50 x 50 10.91 27.28 3665 916
6060 60 x 60 17.3 51.91 6973 1743
8080 80 x 80 32.45 129.8 17438 4359
9090 90 x 90 46.78 210.5 28279 7069
Calc. conditions:
1. The calculations are based on centered loads on profiles with both ends supported.
2. The load capacities (allowable loads) are defined as the load that leads to a deflection of 1/1000 of the profile length. These loads are the max. allowable values and a recommendation for use with the profiles listed here.