Things that are Surprisingly Made from Aluminum

Made from Aluminum

Aluminum is a material you might associate with beverage cans, airplane construction, or even kitchen foil. However, this lightweight, corrosion-resistant metal has a range of applications that go far beyond what meets the eye. In this article, we will explore some of the most unexpected items made from aluminum, revealing the metal’s surprising versatility and why it continues to be a popular choice across various industries. From the arts and household items to high-tech applications, prepare to be amazed at where aluminum shows up in your life.

Origin and Historical Background

Aluminum is the third element in the Earth’s crust, making up approximately 8%. Despite its abundance, this was not isolated as a pure element until relatively late in human history, primarily due to its difficulty separating it from its ores. It wasn’t until 1825 that Danish chemist Hans Christian Ørsted managed to produce a tiny amount of impure aluminum. Later advancements, particularly the Hall-Héroult process in 1886, made it possible to produce aluminum on a commercial scale.

For much of the 19th century, this was considered a precious metal due to the cost and difficulty associated with its production. It was even more expensive than gold at one point. However, advancements in extraction techniques, most notably the development of the Bayer Process for refining bauxite ore, drastically reduced the cost of production. This allowed aluminum to be used in many applications, from the mundane to the highly specialized.

Common Uses of Aluminum

Common Uses


One of the most recognizable uses of this element is in the packaging industry, particularly for beverage cans. Aluminum cans are lightweight, easily recyclable, and provide an effective barrier against light and oxygen, which helps to preserve the contents.


In the aviation industry, it is prized for its strength-to-weight ratio. Aircraft require lightweight and durable materials, and aluminum alloys fit the bill perfectly. Much of an airplane’s body, including the fuselage, wings, and engine components, is made from various alloys.

Construction Materials

It is used in the construction industry, where it is corrosion resistance. It’s an excellent choice for outdoor structures like bridges, commercial buildings, and residential homes. This is used in roofing, window frames, and cladding, offering a combination of durability, low maintenance, and aesthetic appeal.

Why it is the Material of Choice

  • Lightweight

One of the defining characteristics is its low density, which translates to being lightweight. This property is particularly advantageous in applications where reducing weight is beneficial. For instance, lighter materials improve fuel efficiency in vehicles and airplanes, lowering operational costs. This is the “featherweight boxer” in the material world: it packs a strong punch without the extra weight.

  • Corrosion-Resistant

This can resist corrosion thanks to the protective oxide layer on its surface. This makes the element exceptionally well-suited for applications with desirable longevity and durability, especially in humid or salty environments. It’s like an apple that doesn’t brown when sliced; it remains functional and aesthetically pleasing for longer.

  • Excellent Conductor of Electricity

While not as conductive as copper, this is still an excellent conductor of electricity. Given its lighter weight and lower cost, it often becomes the material of choice for long-distance electrical transmission lines. Aluminum can carry the same amount of electricity as copper with only about half the weight, making it a cost-effective alternative. Imagine if you could have a laptop charger that performs the same but is lighter and cheaper; that’s what aluminum brings to the table in electrical applications.

  • Recyclability

One of the standout features is its recyclability. Thanks to recycling, nearly 75% of all aluminum produced is still used today. Aluminum can be melted and changed without losing its inherent qualities, making it a sustainable option in various applications. Think of it as a phoenix, continuously reborn from its ashes, ready for another lifecycle.

foil art

Foil Art

Crafting and Sculpting

When most people think of aluminum foil, they likely envision its culinary uses like wrapping leftovers or cooking. However, this versatile material has also carved out a niche in the world of arts and crafts. Aluminum foil is used for crafting and sculpting projects, both amateur and professional, due to its malleability and ease of manipulation. Artists can easily cut, twist, and shape the foil into intricate designs or figures.

For example, foil can be used to create miniature sculptures, from animals to abstract forms, without requiring specialized equipment. Schools often use aluminum foil in art classes for hands-on projects because it’s an affordable and accessible material. It’s akin to clay that doesn’t need to be fired in a kiln; you can manipulate it freely and see instant results.

Specialized Art Installations

Beyond simple crafts, aluminum foil has also found its way into specialized art installations. Artists have used aluminum foil to create immersive environments, reflect unique light, or make political statements. The material’s reflective properties can create dramatic effects, amplifying light and color in ways other materials cannot.

Some artists use aluminum foil as a canvas, painting or drawing on its surface before using it in an installation. The foil’s texture can add a new dimension to the artwork, giving it a unique appearance that can’t be achieved with traditional canvas or paper.

Smartphone Bodies

iPhones and Other Major Brands

Materials like glass and aluminum often come to mind when considering premium smartphones. Apple’s iPhone, for instance, has frequently employed aluminum in its construction, most notably in models like the iPhone 6 and iPhone 7. But it’s not just Apple; other major brands like Samsung, OnePlus, and Google have also used aluminum to some extent in their smartphone bodies.

Aluminum serves as an excellent middle-ground material for smartphones. It’s more durable than plastic but lighter than stainless steel, providing an optimal blend of strength and portability. Imagine holding a thin paperback book with the robustness of a hardcover; that’s the kind of balance aluminum offers in smartphones.


  • Aesthetic Appeal – Aluminum lends a sleek, modern look to smartphones. Its smooth texture and metallic finish give the devices a premium aesthetic, making them more appealing to consumers seeking a high-end experience.
  • Thermal Conductivity – One of the underappreciated advantages of smartphones is their ability to conduct heat away from internal components. Like how a fan circulates air to cool down a room, aluminum helps to disperse the heat generated by the smartphone’s processor, thus maintaining optimal performance.
  • Durability and Scratch Resistance – While not invincible, it is notably more scratch-resistant than plastic. Its sturdy nature makes it less susceptible to bending or warping over time, prolonging the device’s lifespan. It acts like a well-designed suitcase, capable of taking a few knocks and bumps while protecting what’s inside.
  • Weight Balance – Aluminum’s lightweight nature doesn’t add much heft to smartphones, making them easier to carry. Yet it provides enough weight to give the device a substantial, quality feel in the hand.

Sports Equipment

Baseball Bats

Aluminum has become a common material for baseball bats, especially in amateur leagues and schools. Traditionally, bats were made of wood, but aluminum offers a range of advantages that make it a viable alternative.

  • Enhanced Swing Speed

The lightweight nature of aluminum allows for a quicker and more powerful swing, akin to swinging a wand instead of a heavy staff. This is particularly advantageous for younger players who might not have developed the muscle strength needed for a heavier bat.

  • Durability

Aluminum bats will not break or crack more than their wooden counterparts. They can withstand considerable abuse, much like a durable backpack that endures years of rough handling without tearing.

  • Cost-Effectiveness

While the initial investment in an aluminum bat might be higher than a wooden one, its durability means it often lasts longer, thus proving more cost-effective in the long run.

Golf Clubs

Aluminum is also a popular material in the construction of golf clubs, particularly in the shaft and sometimes in the head for certain clubs like putters.

  • Flexibility and Control

Aluminum shafts offer a good amount of flex, allowing for better control over the shot. It’s similar to using a flexible fishing rod that provides more control over the line, enabling you to make subtle adjustments during the swing.

  • Lightness and Comfort

The lightweight properties make it easier to carry a set of clubs around the course and reduce fatigue during play. It’s like wearing a pair of lightweight sneakers instead of heavy boots; you can move more freely and comfortably.

  • Customization

Aluminum allows for a higher degree of customization in golf clubs. Manufacturers can easily adjust the properties of the aluminum alloy to match a player’s specific needs, much like custom-tailoring a suit to fit perfectly.

automotive part

The Automotive Sector

Engine Components

Aluminum has steadily gained ground in the automotive industry, particularly in constructing engine components. Its properties have made it an attractive alternative to traditional materials like iron and steel.

  • Weight Reduction

One of the most prominent advantages of aluminum engine components is the significant weight reduction. A lighter engine means a lighter vehicle, leading to improved fuel efficiency. Think of it as swapping out heavy hiking boots for lightweight running shoes; you’ll expend less energy moving forward.

  • Heat Dissipation

Aluminum is an excellent conductor of heat, an invaluable property in engine components. Efficient heat dissipation allows the engine to maintain optimal operating temperature, increasing lifespan and performance. It’s akin to wearing moisture-wicking fabric to keep your body cool during a workout.

Cylinder Heads

Cylinder heads are critical components that form the top of the engine’s combustion chambers. Aluminum has become a popular choice for manufacturing these parts for several reasons.

  • Thermal Efficiency

Aluminum cylinder heads improve thermal efficiency, as the material can quickly absorb and dissipate heat generated during combustion. This quality helps to optimize the engine’s performance. Imagine using a sponge that quickly soaks up liquid spills; aluminum similarly “soaks up” heat, keeping the engine running efficiently.

  • Cost Savings

While aluminum cylinder heads may cost more upfront, they often result in long-term savings. Their lightweight nature contributes to greater fuel efficiency, lowering vehicle lifespan operational costs.


The radiator is crucial in cooling the engine and maintaining its performance. Aluminum is often the material of choice for modern radiators.

  • Improved Cooling Efficiency

Due to its excellent thermal conductivity, aluminum helps the radiator operate more efficiently, thereby maintaining an ideal engine temperature. It’s similar to how a good air conditioner quickly cools a room, maintaining a comfortable environment.

  • Longevity

Aluminum radiators are highly resistant to corrosion, which prolongs their lifespan. The corrosion resistance means fewer concerns about leaks or failures, akin to using a stainless steel water bottle that won’t rust over time.

Electric Cars

Electric vehicles (EVs) represent a growing segment of the automotive industry, and aluminum is increasingly becoming a material of choice for various components, including battery housings and structural elements.

  • Battery Housings

One of the components in an electric vehicle is the battery, which needs housing to protect and keep it in place. Aluminum is often used for this purpose, and good reasons.

  • Lightweight yet Protective

Since batteries can be heavy, using a lightweight material like aluminum for the housing is beneficial. This property helps offset the batteries’ weight, making the vehicle more efficient. It’s similar to using lightweight but sturdy luggage when traveling; you get the protective benefits without the additional burden.

  • Thermal Management

Battery performance is strongly influenced by temperature. Aluminum’s excellent thermal conductivity makes it effective for managing the heat generated by the battery, similar to how a well-designed thermal mug maintains the temperature of your drink.

Structural Elements

Besides battery housings, aluminum is utilized in various structural elements of electric vehicles, from the chassis to body panels.

  • Weight Efficiency

Aluminum’s low density allows for a lighter overall vehicle weight, a crucial factor in electric cars. Lower weight translates to increased range, making it easier for the vehicle to travel farther on a single charge. Think of it as wearing a lightweight backpack on a hike; you can go longer distances without tiring as quickly.

  • Rigidity and Safety

While it’s lightweight, aluminum doesn’t compromise much on strength. The metal provides the necessary rigidity to the vehicle’s structure, offering safety benefits. It’s akin to the frame of a well-designed tent, which remains stable and secure even in strong winds.

  • Environmental Benefits

The recyclability of aluminum adds a layer of environmental sustainability to electric vehicles, aligning with the eco-friendly ethos of this car segment. Picture it as using reusable shopping bags instead of single-use plastic bags, aligning with a broader commitment to environmental sustainability.

 plumbing kitchen

In the Home

Aluminum has found its way into constructing outdoor decks, offering advantages that make it an increasingly popular alternative to traditional wood or composite materials.

Water-Resistant Properties

One of the most notable benefits of using aluminum for decking is its resistance to water and moisture. Unlike wood, which can rot, or certain composites that might swell, aluminum remains unaffected by water exposure. This makes it ideal for use in environments where rain or water exposure is frequent. It’s comparable to a waterproof watch for swimming—you get the function without worrying about damage.

  • Easy Maintenance

Because of its water-resistant nature, aluminum decking requires less maintenance to prevent mold or mildew. This makes it a convenient option for those who prefer a low-maintenance outdoor space, similar to choosing artificial turf over natural grass.

Weight and Structural Benefits

  • Load-Bearing Capabilities

Despite being lightweight, aluminum offers impressive load-bearing capabilities. This is particularly useful for decks that need to support a considerable amount of weight, such as furniture or hot tubs. Imagine using a lightweight but strong material like carbon fiber for a bicycle frame; it offers the benefits of strength without the downside of heaviness.

  • Long Lifespan

The structural benefits extend to the material’s durability. An aluminum deck is likely to last much longer than a wooden one, with less risk of warping, cracking, or other structural deterioration. It’s similar to building a house with bricks rather than wooden panels; the former offers a longer lifespan with fewer structural concerns.

  • Versatility in Design

Aluminum allows for a high degree of customization and is available in various colors and textures. This means you can tailor the look of your deck to match the aesthetic of your home, much like choosing custom upholstery for your furniture.

Cookware and Kitchen Appliances

Aluminum is commonly used in various cookware and kitchen appliances, including pots and pans, blenders, and other small devices. Its popularity is attributed to factors ranging from heat conductivity to cost-effectiveness.

Pots and Pans

Aluminum is often used to construct pots and pans, sometimes as the core material and others as a layer within a multi-layered construction.

  • Efficient Heat Conduction

One of the standout attributes of aluminum cookware is its excellent heat conductivity. When you place an aluminum pan on the stove, it heats up quickly and distributes the heat evenly across the surface. This is similar to how a sponge soaks up water uniformly, ensuring you don’t end up with hot or cold spots in your food.

  • Lightweight and Maneuverable

The lightness of aluminum makes pots and pans easy to handle, particularly when you’re moving them around, flipping food, or transferring dishes from the stovetop to the oven. It’s akin to using lightweight gardening tools that make the work less strenuous.

  • Cost-Effectiveness

Aluminum cookware is generally less expensive. While it might not offer the same longevity as some other materials, its cost-effectiveness makes it accessible for many consumers, much like choosing a budget-friendly laptop that performs well for basic tasks.

Blenders and Other Small Appliances

Aluminum is also found in various small kitchen appliances like blenders.

  • Durability and Stability

Aluminum balances strength and weight, contributing to small appliances’ durability and stability. For instance, an aluminum blender base can be sturdy enough to securely hold the motor and other components, similar to how a well-balanced tripod supports a camera.

  • Aesthetic Appeal

The modern appearance of aluminum can add a touch of style to kitchen appliances. It has a versatile aesthetic that can blend well with other kitchen decor, much like how a classic black dress can fit into various social settings.

Indoor Furniture

The application of aluminum also extends to indoor furniture, which is particularly prevalent in creating chairs and tables. Its properties make it suitable for various design trends, including minimalism.

Aluminum Chairs and Tables

  • Durability

Aluminum is a strong material that can withstand significant wear and tear, making it well-suited for furniture that sees frequent use. Think of it as using a durable backpack for daily commuting; it’s built to last.

  • Lightweight

Despite its strength, aluminum is lightweight, so chairs and tables made from this material are easy to move around. This is particularly useful in spaces that need to be reconfigured frequently, similar to lightweight modular shelving systems that can be easily rearranged.

  • Easy to Clean

Aluminum furniture is relatively easy to maintain. A simple wipe-down is often enough to keep chairs and tables looking fresh, akin to using a dry-erase board that easily wipes clean, leaving no stains or marks.

Minimalistic Design Trends

Aluminum’s sleek and modern appearance makes it ideal for minimalistic design trends that favor clean lines and uncluttered spaces.

  • Versatility in Aesthetics

Aluminum can be treated to achieve a variety of finishes, from matte to glossy, fitting seamlessly into a minimalistic design palette. It’s like having a versatile piece of clothing.

  • Space Optimization

The streamlined design of aluminum furniture aligns with minimalistic principles that optimize space. You can make the most out of limited square footage by choosing slender but strong aluminum chairs or tables, similar to using slim, wall-mounted storage units to maximize space in a small apartment.


High-Tech and Specialized Uses


Aluminum is a versatile material widely used in astronomy, particularly in the construction of telescopes. From reflective coatings to structural elements, aluminum offers benefits that make it ideal for this specialized equipment.

  • Reflective Coatings

One of the primary uses of aluminum in telescopes is as a reflective coating on the mirrors that gather and focus light.

  • High Reflectivity

Aluminum has excellent reflective properties, allowing the mirrors to capture more light and, in turn, provide clearer images. This is somewhat akin to using a high-resolution camera sensor that can capture more detail in a photograph.

  • Resistance to Environmental Factors

Aluminum coatings are often more resistant to environmental factors such as oxidation than other metals like silver. This results in longer-lasting mirrors that require less frequent re-coating. Imagine using stainless steel cookware that resists rusting and tarnishing over time.

Structural Elements Made from Aluminum

Aluminum is also commonly used to construct telescope frames and other structural components.

  • Strength-to-Weight Ratio

Its excellent strength-to-weight ratio makes aluminum a good choice for the structural elements of telescopes. The material offers a balance of sturdiness and lightness, similar to using high-strength alloys in bicycle frames.

  • Ease of Fabrication

Aluminum is easy to fabricate, which allows for more complex telescope designs. It’s comparable to working with softwood in carpentry, where the material can be easily shaped into intricate designs.


Aluminum is confined to Earth-bound telescopes and is a common material in satellites, particularly in their solar arrays and outer shells.

  • Solar Arrays

Satellites often use aluminum in their solar arrays to capture solar energy.

  • Electrical Conductivity

Aluminum’s ability to conduct electricity well makes it ideal for components that transfer the electrical energy captured by solar cells to the satellite’s systems. This is somewhat like using copper wiring in a home to transfer electrical current efficiently.

Outer Shells

The external parts of many satellites are also constructed with aluminum.

  • Thermal Conductivity

Its good thermal conductivity helps dissipate the heat from onboard systems, preventing overheating. It’s similar to using heat sinks in computer systems to manage thermal conditions.

  • Low Density

The low density of aluminum is advantageous for reducing the satellite’s overall weight, thereby reducing the cost of launching it into space. This is like choosing lightweight materials for backpacking equipment to make the journey less strenuous.

recycle material

Environmental Impact and Sustainability


The widespread use of aluminum across various sectors necessitates an examination of its environmental impact and sustainability. The two main aspects to focus on here are aluminum recycling and energy consumption during aluminum production.

Steps in Recycling Aluminum

Collection: Aluminum products are collected from curbside pickups, recycling centers, and drop-off locations.

Sorting and Cleaning: The collected aluminum is sorted by type and cleaned to remove contaminants.

Shredding: Aluminum is then shredded into smaller pieces to facilitate the melting process.

Melting: Shredded aluminum is melted in furnaces to produce molten aluminum.

Purification: Impurities are removed from the molten aluminum through chemical processes.

Cooling and Solidification: The purified molten aluminum is cooled to form ingots, sheets, or other aluminum shapes.

Fabrication: These aluminum forms are then fabricated into new products.

The recycling process can be compared to a loop, similar to the water cycle where water evaporates, condenses, and precipitates, only to be evaporated again.

Environmental Benefits

Recycling aluminum substantially reduces the need for bauxite ore mining. It also lowers greenhouse gas emissions compared to the production of new aluminum. The benefit is akin to reusing glass bottles instead of producing new ones, which saves both raw materials and energy.

Energy Consumption

Producing aluminum from raw materials is energy-intensive, raising sustainability concerns.

Amount of Energy Required

Extracting aluminum from bauxite ore and its subsequent refinement into pure aluminum involves using much electricity. This can be likened to running a large industrial facility requiring significant electrical power.

Reduction Methods

Several strategies are employed to reduce the energy consumption in aluminum production:

Technology Upgrades: Implementing more efficient technologies can reduce energy usage. This is like replacing old household appliances with energy-efficient models.

Alternative Energy Sources: Utilizing renewable energy sources can offset the environmental impact. It’s like powering your home with a solar panel system instead of coal-based electricity.

Increasing Recycling Rates: As mentioned earlier, recycling aluminum uses less energy than producing new aluminum. It’s comparable to recharging and reusing batteries instead of disposing of them and buying new ones.



Surprising Facts about Aluminum

Aluminum might be commonplace today, but its history and certain applications are filled with surprising facts that many people may not be aware of.

Ancient History Background

  • Misidentified as Precious Stones

Ancient civilizations like the Egyptians and Romans used aluminum silicates in pottery and dyes, not knowing that they contained aluminum. These aluminum-bearing compounds were often mistaken for precious stones or minerals. Think of it like discovering that a costume jewel is made from a valuable material.

  • Mysterious Artifacts

Aluminum artifacts dating back thousands of years have been found, perplexing historians because the extraction of aluminum wasn’t developed until the 19th century. The presence of such artifacts is akin to finding a modern electronic device in an ancient archeological site; it challenges our understanding of historical technological capabilities.

Aluminum’s Involvement in Space Missions

  • Moon Landings

One of the most awe-inspiring facts is that the element was a core component of the Apollo 11 spacecraft that landed the first humans on the Moon. Using this element in a significant historical event is like using regular household items in a Nobel Prize-winning scientific experiment—something becoming part of something extraordinary every day.

  • Satellite Hulls

As previously mentioned, this is commonly used in satellites. What’s intriguing is that this everyday material is floating above us in space right now, serving crucial roles in communications, weather monitoring, and scientific research. It’s like discovering that the ink used in a common pen is also used to write ultra-secure government documents.

High Cost in the 19th Century

  • More Expensive Than Gold

In the early 19th century, it was more expensive than gold due to its difficulty in extracting it from ore. It was considered a precious metal and displayed alongside the French Crown Jewels. The shift from precious to ubiquitous is similar to a rare book becoming a bestseller with millions of copies in print.

  • Napoleonic Displays

Because of its high cost and rarity, it was used for special honors and presentations. French Emperor Napoleon III is said to have had cutlery reserved for his most esteemed guests, while others used gold. It’s comparable to serving a rare vintage wine only to VIP guests while serving a widely available wine to others.

Element Surrounding Us

The journey of aluminum from its obscure origins in ancient history to its omnipresent role in modern life is fascinating. It’s a material that has seamlessly woven itself into the fabric of our daily lives, from the mundane to the extraordinary—from soda cans and kitchen utensils to satellites and space missions. Its versatility is amplified by its unique properties, such as lightness, strength, and recyclability, making it a subject of environmental concern and innovation for sustainability. Whether you’re peering through a telescope, scrolling through your smartphone, or driving an electric car, the chances are that you’re interacting with this remarkable material in ways you’ve never imagined.


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