Aluminium End Caps

Nelsons CNC aluminium end caps are designed to fit in the end of an extrusion permanently with a tight fit, knocked in using a rubber mallet, with no welding or silicone required. Our end caps are made in-house on our CNC machining centres with precise accuracy to guarantee the perfect fit.

Nelsons CNC supplies aluminium end caps in a wide range of shapes and sizes to suit common extrusion profiles across fabrication, glazing and structural projects.

All aluminium end caps are manufactured at a consistent 6 mm thickness, while our aluminium hole plugs are produced at 3 mm thickness. Each end cap is press-fit and designed to tightly close the end of the extrusion without the need for welding. Installation is easy and secure. Simply tap the end cap into place using a rubber mallet until firmly fitted.

Our round aluminium end caps can be powder-coated either before or after installation. We partner with Kote It, a trusted Australian powder coating specialist with extensive experience coating our aluminium end caps to achieve durable and consistent finishes.

  • Square End Cap - Square Edge Square End Cap - Square Edge

    Square End Cap - Square Edge

    Square End Cap - Square Edge
    From $2.70
    From $2.70
    Our aluminium end caps are available in a range of sizes (shown in mm)
    Select your size
  • Square End Cap - Radius Edge Square End Cap - Radius Edge

    Square End Cap - Radius Edge

    Square End Cap - Radius Edge
    From $2.70
    From $2.70
    Our end caps are available in a range of sizes (shown in mm).
    Select your size
  • Rectangle-End-Cap-Square-1-and-3mm Rectangle End Cap - Square Edge

    Rectangle End Cap - Square Edge

    Rectangle End Cap - Square Edge
    From $2.70
    From $2.70
    Our aluminium end caps are available in a range of sizes (shown in mm)
    Select your size
  • Rectangle End Cap - Radius Edge Rectangle End Cap - Radius Edge

    Rectangle End Cap - Radius Edge

    Rectangle End Cap - Radius Edge
    From $2.70
    From $2.70
    Our aluminium end caps are available in a range of sizes (shown in mm)
    Select your size
  • Round End Cap Round End Cap

    Round End Cap

    Round End Caps
    From $2.80
    From $2.80
    Our aluminium end caps are available in a range of sizes (shown in mm)
    Select your size
  • Hole Plugs Hole Plugs

    Hole Plugs

    Hole Plugs
    From $2.90
    From $2.90
    Our hole plugs are available in a range of sizes (shown in mm). Each plug is precisely CNC-machined from high-quality 6060 T5 aluminium, known for its excellent strength-to-weight ratio, corrosion resistance and smooth surface finish. Designed for a flush, professional look, these aluminium hole plugs provide a permanent mechanical fit without the need for adhesives or welding. With a total thickness of 3mm and a subtle chamfer on the edge, they install cleanly and sit securely in place — ideal for both indoor and outdoor applications where durability, performance and visual appeal matter.
    Select your size
  • Glazing Caps Glazing Caps

    Glazing Caps

    From $3.50
    From $3.50
    Our aluminium end caps are available in a range of sizes (shown in mm)
    Select your size
  • Elliptical Louvre End Cap Elliptical Louvre End Cap

    Elliptical Louvre End Cap

    From $4.65
    From $4.65
    Our aluminium end caps are available in a range of sizes (shown in mm)
    Select your size
  • Connect Post Caps Connect Post Caps

    Connect Post Caps

    Connect Post Caps
    From $13.45
    From $13.45
    Our aluminium end caps are available in a range of sizes (shown in mm)
    Select your size
  • Balustrade Cap Oval-Balustrade-Cap2

    Balustrade Cap

    From $6.00
    From $6.00
    Our aluminium end caps are available in a range of sizes (shown in mm)
    Select your size

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Aluminium end caps for a clean, secure finish

Nelsons CNC aluminium capping is engineered for performance, durability and a refined finish across a wide range of structural and fabrication projects. Whether you're working on commercial, architectural or residential builds, our end caps are the finishing touch your extrusion system needs.

Common applications include:

  • Aluminium fencing, balustrades and gates
  • Structural and architectural framing
  • Commercial glazing systems
  • Custom fabrication and aluminium extrusion projects
  • Signage and display structures

Designed to be tapped into place with a rubber mallet, these press-fit end caps sit flush with the extrusion, creating a seamless edge that improves safety, protects internal surfaces and elevates the overall look of your project.


Why choose aluminium end caps from Nelsons CNC

Our end caps are made in-house on CNC machining centres to ensure unmatched consistency, precision and quality. Here's why our customers choose us:

  • Premium 6060 T5 aluminium — Each end cap is machined from high-grade 6060 T5 aluminium; lightweight yet incredibly strong, with excellent corrosion resistance. It’s ideal for long-term performance and perfectly suited to powder coating for a clean, professional finish.
  • Reliable press-fit design — Our end caps are engineered for a tight, secure press-fit. No welding, adhesives or silicone are needed for a permanent installation that holds firm in structural and architectural applications.
  • Consistent 6 mm thickness — All end caps are precision-machined to a uniform 6 mm thickness. This provides reliable durability, impact resistance and a flush, stable finish across a range of aluminium extrusion profiles.
  • Simple, tool-free installation — No special equipment is required; just a rubber mallet to tap the cap into place. It’s an easy and efficient solution that works on-site or in the workshop. Check out our installation guide for step-by-step instructions and tips to ensure a secure, professional fit.
  • Powder coat–ready compatibility — Our aluminium end caps are ready for powder coating either before or after installation. For professional, consistent results, we work with Kote It, our powder coating partner with experience finishing our full product range.


Custom sizing and support

Need something outside our standard size range? We can help. Nelsons CNC offers custom-sized aluminium end caps for unique extrusion profiles and non-standard dimensions. Request a custom size, and our team will work with you to achieve the right fit for your application.


Choose aluminium end caps from Nelsons CNC

Explore our full range of aluminium capping designed to deliver clean finishes and long-lasting performance across fabrication, glazing and structural applications. With Nelsons CNC, you get aluminium end caps designed to match your extrusion size, allowing for secure installation with no welding required.

If you need help choosing the right size or style, our team is here to guide you and ensure you order the right solution for your project. Contact us today to get started.

FAQs

What exactly are aluminium end caps or aluminium capping?

Aluminium end caps, also referred to as aluminium capping, are solid components designed to close off the open ends of aluminium extrusions. They provide a clean, finished look while helping protect the internal profile from impact damage.

Aluminium end caps also help improve safety by covering sharp edges and are commonly used to give projects a more professional and complete appearance across a wide range of applications.

Why should I use aluminium end caps, and why not leave the profile open?

Leaving an aluminium profile open can expose sharp edges and allow dirt or moisture to collect inside the extrusion. Aluminium end caps help improve safety, protect the profile and extend its lifespan by sealing the exposed end.

When and where are aluminium end caps most commonly used?

Aluminium end caps are commonly used in the fabrication of glazing posts, balustrades, framing systems, signage and architectural projects. They are suitable for both indoor and outdoor applications where a clean finish and added protection are required.

Why choose aluminium end caps when plastic options are common?

Aluminium end caps offer greater strength, durability and visual consistency compared to plastic alternatives. They are better suited for heavy-duty applications and projects where long-term performance and a premium finish are important.

How are aluminium end caps installed and is it difficult?

Installation is simple. Nelsons CNC aluminium end caps are press fit and designed to match your extrusion size. No silicone or welding is required. To install, tap the end cap into place using a rubber mallet until it is firmly fitted.

How do I choose the right end cap for my project?

Check the shape and internal dimensions of your aluminium extrusion, along with the required finish and application environment. Ensuring the end cap matches the extrusion size is essential for a secure fit and clean result. Pay close attention to the external dimensions of your extrusion and the wall thickness of the material.

If I order from a supplier, what should I ask to make sure I get the right end caps?

Ask about extrusion compatibility, thickness, installation method and manufacturing quality. It is also worth confirming if the end caps are press fit and whether they can be powder-coated if required.

How are aluminium end caps from Nelsons CNC different from generic caps?

Nelsons CNC aluminium end caps are precision-manufactured in Australia and designed to match specific extrusion sizes. They are made for secure press fit installation, consistent thickness and reliable performance across professional fabrication and construction projects.

Press fit aluminium end caps

Square End Caps

Tightly fitting Round end caps

Round End Caps

Aluminium End Caps