The Shapemakers by The Aluminum Extruders Council

Hosted by The Aluminum Extruder's Council

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Sep 2025

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The Shapemakers from the Aluminum Extruders Council is a podcast series that provides valuable information about timely and relevant aluminum extrusion topics. Whether it's details about the tariffs on imports of aluminum profiles from China, how building and energy codes may affect aluminum extrusion products, or the industry's efforts to attract and train the next generation of aluminum extrusion designers, engineers and employees, The Shapemakers podcast promises to enlighten and inspire all who listen. This show will appeal to all those interested in how market, economic and industry forces are shaping the aluminum extrusion world – whether you're an AEC member, an aluminum industry professional or aluminum extrusion customer. This show has something for everyone interested in learning more about aluminum extrusions.

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September 8, 2025Episode 6723 min

Safety + HR Workshop Preview (with Melvin Mitchell)

Host: Jason Weber, President, Aluminum Extruders Council (AEC) Guest: Melvin "Mel" Mitchell, EHS Director, MI Metals Episode Summary Jason sits down with longtime safety pro Melvin Mitchell to preview AEC's upcoming Safety & HR Workshop + Plant Tour—two tightly packed days at the Westin Atlanta Airport, October 28–29. Why combine Safety and HR? Because that's how the real world runs: overlapping responsibilities, shared culture, and one goal—send everyone home safe while building great teams. You'll hear what's on the agenda (from molten metal and maintenance safety to employment law and recruiting more women and veterans), why the Bonnell Aluminum—Noonan plant tour is a can't-miss (three+ years with no recordable incidents), and exactly why the best ideas often spark on the post-session barstool. Register early—bus seats for the plant tour are limited, and early/group rates sweeten the deal. The event is open to members and non-members, with sponsorships available. Why Listen Get a field-tested map of the two-track program (Safety + HR) and how they connect. Learn how culture, behavior, and systems turn safety from posters into performance. Steal practical ideas you can apply next shift—not next year. Program Highlights Safety Track Keynote: Changing mindsets and driving a safety culture transformation (Chris Andrews, EHS Manager, Bonnell Aluminum—Noonan) Workshops & Breakouts: Cast house & molten metal safety (and why your scrap prep matters) Emergency preparedness & first-responder training Maintenance tech safety: practical risk reduction Human behavior: common pitfalls and proven fixes Safety panel: interactive problem-solving with peers HR Track Leadership Keynote: "The Power Position"—shifting cultures and driving results (Emily Nichols-Mitchell, Accelerations Group) Sessions: Employment law essentials: ICE/I-9, workers' comp, hot-button issues (Philip Russell, Ogletree Deakins) Integrating veterans into manufacturing teams (John Buckley, Textron Aviation) Reaching women in operations—expanding the talent pipeline Future-of-work challenges (Performance Point LLC) HR panel: candid Q&A on today's toughest people challenges Plant Tour Bonnell Aluminum — Noonan, GA See the systems, standards, and behaviors behind 3+ years with no recordable incidents—a live look at excellence in action. Who Should Attend Safety leaders, HR pros, operations managers, plant supervisors, and anyone who wears both hats (because… many do). Key Takeaways Safety and HR are two sides of one culture—align them and performance compounds. Behavior + systems beat posters and pep talks. Peer networking accelerates solutions you can deploy immediately. Seeing best-in-class operations in person changes how you lead back home. Logistics & Registration When/Where: October 28–29, Westin Atlanta Airport (not downtown—easy in/out). Plant Tour: Wednesday morning; limited coach capacity—register early to secure a seat. Pricing: Early-bird and multi-attendee discounts available. Open Access: AEC members and non-members welcome. Sponsorships: Opportunities available for suppliers and extruders—helps offset costs and boosts visibility. Pro tip from Mel: Don't leave your hotel to chance—book early. Atlanta traffic doesn't care about your first session. Register early, bring your team, and claim those tour seats. (And if you're a supplier or extruder, consider a sponsorship—it fuels the content and keeps costs in check.) https://members.aec.org/events/EventDetails.aspx?id=1970710&group=

August 11, 2025Episode 6629 min

Unlocking Opportunities at The Aluminum Summit - Atlanta

Summary In this conversation, Jason Weber and Mark Butterfield discuss the upcoming Aluminum Summit, highlighting its significance as a major event for the aluminum industry. They delve into the various workshops, networking opportunities, and keynote speakers that will be featured, emphasizing the importance of learning and collaboration within the industry. The discussion also touches on market trends, challenges, and the need for the next generation of professionals in the field. Takeaways The Aluminum Summit occurs every four years, with the next one in September. Networking opportunities at the summit are invaluable for industry professionals. Workshops will cover a wide range of topics, including anodizing and extrusion. The Extrusion Excellence Workshop is a key learning opportunity for attendees. General sessions will address critical industry issues like trade and tariffs. The keynote speaker, Gene Marks, will provide insights on navigating economic challenges. Focus sessions will cater to various aspects of the aluminum industry. Understanding market trends is essential for industry growth and adaptation. The summit aims to foster collaboration between extruders and finishers. Encouraging the next generation of professionals is vital for the industry's future. For details about the Aluminum Summit Visit - https://members.aec.org/page/aluminum-summit-about

June 10, 2025Episode 6511 min

Investing in the Future: How the AEC is Tackling Workforce Development with Apprenticeship Programs

Episode Summary: In this episode of SHAPEMAKERS, host Bennett McEvoy, President of Western Extrusions and AEC Board Member, is joined by Duncan Crowdis, former CEO of Bonnell Aluminum and AEC Workforce Development lead. Together, they shine a light on the aluminum extrusion industry's growing need for skilled talent—and what the Council is doing about it. With over 175 extrusion plants operating across 37 states, the industry supports more than 40,000 U.S. jobs. But as experienced workers retire and demand for aluminum products rises, attracting and training the next generation of skilled professionals has become mission-critical. Bennett and Duncan dive into the AEC's multi-year effort to launch industry-wide apprenticeship programs—starting with maintenance technicians and expanding to extrusion press operators and die technicians, two of the industry's most essential roles. Listeners will get a behind-the-scenes look at how the AEC collaborated with the U.S. Department of Labor, developed tailored training programs, and is now preparing to launch a Train-the-Trainer initiative in 2026. What You'll Learn: Why aluminum extrusions are everywhere—even if you don't always see them The crucial role of skilled maintenance workers and press operators How apprenticeship programs are helping to future-proof the extrusion workforce What's ahead for the AEC's Train-the-Trainer initiative How companies can get involved right now Resources & Links:  Learn more about the AEC Apprenticeship Program: www.AEC.org  Contact the AEC about workforce development: info@aec.org  Want to join the extrusion industry? Explore career opportunities and resources on the AEC website

January 7, 2025Episode 6438 min

2024 Year in Review w/ Mark Butterfield

In this episode, Jason Weber and Mark Butterfield reflect on the AEC's 75th anniversary, discussing the organization's impact on the industry and the importance of adapting to change. They outline strategic planning for 2025, upcoming events, and the significance of training and development for members. The conversation also highlights the need for effective communication and member engagement, as well as the challenges posed by trade dynamics. Looking ahead, they emphasize the importance of collaboration and a unified voice within the industry. Takeaways 2024 was a significant year for the AEC, marking its 75th anniversary. The AEC has played a crucial role in shaping the industry over the decades. Strategic planning for 2025 is essential to adapt to industry changes. Upcoming events will focus on member engagement and professional development. Training programs for die correctors and press operators are being developed. Effective communication is key to understanding member needs. Trade challenges remain a top priority for the AEC's strategy. The annual meeting serves as a vital networking opportunity for members. Collaboration among members enhances the value of the AEC. Looking forward to 2025, the AEC aims to serve its members better.

November 27, 2024Episode 6314 min

Aluminum Extrusion: The circular economy - A Sustainable Future

In this episode of ShapeMakers, Lynn Brown and Rue Rogers discuss the intersection of aluminum extrusion and the circular economy. They explore how aluminum can be recycled effectively, the importance of maintaining materials in circulation, and the role of scrap in the industry. The conversation highlights the sustainability initiatives within the aluminum extrusion sector and the potential for increased recycling efforts. Takeaways The circular economy aims to keep materials in circulation indefinitely. Aluminum has a high recycling rate, with 75% still in use today. Recycling aluminum does not degrade its properties, allowing for high-quality applications. Aluminum can be used over and over without any degradation of properties. The industry uses a mix of virgin and recycled aluminum, typically around 25% virgin and 75% scrap. Recycled aluminum billet can be used just like billet made from prime or virgin aluminum; it does not need to be downgraded to be used in lower performance applications because of its scrap content like other materials. Post-consumer scrap includes materials from product end-of-life, such as old windows and doors, wheels, wire and other building components. Anodized aluminum can be recycled similarly to unfinished aluminum, while painted aluminum poses challenges. The infrastructure for collecting and processing aluminum scrap is well-established in North America. There is potential to increase the use of post-consumer scrap in the industry. Aluminum's corrosion resistance contributes to its long lifespan in applications. The aluminum extrusion industry is actively working on improving recycling processes. Learn more about the Aluminum Extruders Council at aec.org

July 16, 2024Episode 6238 min

Mark Butterfield - President of Manufacturing, MX Holdings

Welcome to Shape Makers, the podcast series from the Aluminum Extruders Council (AEC). AEC represents over 75% of North America's aluminum extrusion production. In this series, we explore key issues affecting extruders, suppliers, and users of aluminum extruded products. Our guest speakers dive into topics like aluminum extrusion Fairtrade cases, industry efforts to attract and retain skilled workers, how extrusion products meet stricter building and energy codes, the increasing use of extrusions in vehicles, and much more. Join Jason Weber from the AEC as he chats with industry veteran Mark Butterfield, the newly appointed chairman of AEC. Mark shares his journey in the aluminum extrusion industry, his vision for AEC, and the importance of engaging with the Council's committees and initiatives. Learn about the rich history of the AEC, the legacy of foundational companies, and the value of networking and collaboration within the industry. Whether you're a seasoned professional or new to the field, Shape Makers offers insights and inspiration to help you navigate the dynamic world of aluminum extrusions. So sit back, relax, and get ready to learn more about the innovations and challenges shaping the industry. :::::::: About Mark Butterfield - President of Manufacturing, MX Holdings With more than 30 years of experience in the aluminum extrusion industry, Mark Butterfield serves as President of Manufacturing MX holdings which includes Pennex. An established industry leader, he also serves the Aluminum Extruders Council (AEC) in multiple positions, including that of Vice Chairman of the Board of Directors, Chairman of the Automotive Committee, and Vice Chairman of Extrusion Technology 2024. Connect with Mark on Linkedin

April 23, 2024Episode 6118 min

Environmental Tool - Extrusion & Decarbonization - Part 1

Lynn Brown of the AEC and Shane Tredup of Custom Aluminum discuss decarbonization efforts in the extrusion industry, highlighting the growing demand from customers for information on carbon footprint, scope one, two, and three emissions, and decarbonization plans. Industry tool for aluminum extruders to track carbon emissions. ACC aims to create industry tool for extruders to track carbon footprint and reduce it by 20%. Tool to calculate carbon emissions for extruders, covering multiple products and methodologies. Discover the tool's capabilities, including sensitivity analysis and real-time what-if scenarios, to help extruders understand the impact of changes to their business on their carbon intensity. The tool will be useful for extruders to understand their own situation and make improvements and plans to do a separate podcast on the tool's functionality and new guidelines for granularity and reporting. About The AEC: Follow AEC on LinkedIn for the latest updates and industry insights. Stay informed about the Aluminum Extruders Council by visiting aec.org and following us on Twitter. Stay Tuned for More SHAPEMAKERS: Don't miss out on future episodes of SHAPEMAKERS where we continue to explore the stories, innovations, and trends shaping industries worldwide. Subscribe on Apple Podcasts, Spotify, or your favorite podcast platform. Thank you for joining us on this enlightening journey through the world of aluminum extrusion. Until next time, keep shaping the future!

April 17, 2024Episode 6019 min

ET'24 Preview with Rob Nelson of ALMAG Aluminum

Welcome back to another riveting episode of SHAPEMAKERS, where we explore the fascinating world of shaping industries and innovations. In this special edition, Jason Weber, the VP of Operations and Government Affairs for the Aluminum Extruders Council (AEC), sits down with our distinguished guest Rob Nelson Executive Vice President at ALMAG Aluminum. ALMAG ALUMINUM ALMAG's history began in 1953, when Edward Peacock founded ALMAG Aluminum and Magnesium Ltd. manufacturing decorative door grilles. ALMAG's first aluminum extrusion press started production in 1959. Mr. Peacock envisioned a prosperous business with an ambition to build good products with good people and repeat business. Today, under the leadership of his son, Bob, our passion for quality and service remains strong. For more on ALMAG visit - ALMAG Aluminum / Made possible. – Design • Extrude • Fabricate • Finish About The AEC: Follow AEC on LinkedIn for the latest updates and industry insights. Stay informed about the Aluminum Extruders Council by visiting aec.org and following us on Twitter. Stay Tuned for More SHAPEMAKERS: Don't miss out on future episodes of SHAPEMAKERS where we continue to explore the stories, innovations, and trends shaping industries worldwide. Subscribe on Apple Podcasts, Spotify, or your favorite podcast platform. Thank you for joining us on this enlightening journey through the world of aluminum extrusion. Until next time, keep shaping the future!

April 16, 2024Episode 5940 min

Process Analysis+Optimization - ET'24 In Conjunction Workshop

Jason Weber visits with Prof. Lorenzo Donati about the upcoming ET'24 In-Conjunction Workshop on Process Analysis & Optimization 8:30 a.m. - 5:00 p.m. Fee: $595 Instructors: Professors from the Manufacturing Technologies Group at the University of Bologna, Italy Learn how to optimize and analyze the aluminum extrusion process in this one-day intensive course from the experts at the Manufacturing Technologies Group at the University of Bologna in Italy. They have worked extensively with European extruders and die makers to optimize die design, improve welding phenomena in extrusion dies, increase die life, and analyze final microstructure of extruded profiles. This course covers the following topics: Introduction to practical and analytical extrusion concepts Material flow and Friction in direct extrusion Die failure modes and die life prediction Seam welds, welding criteria and profile strength Charge welds and process performance Microstructure evolution and Streaks formation mechanisms. About Prof. Lorenzo Donati Lorenzo Donati is Associate Professor in Manufacturing Technologies in the "Department of Engineering for Industry" in the School of Engineering (Forlì Campus) of Alma Mater Studiorum -University of Bologna. He received the Ph. D. in the course on "Engineering of manufacturing systems, of metallurgy and applied measurements" of the Polytechnic University of Marche (Ancona, IT) with a dissertation on "Seam weld formation during aluminum extrusion: FEM simulation and experimental verification of the mechanical and aesthetical proprieties". The research field concerns the analysis and optimization of forming processes with specific focus on the extrusion of light alloy: seam and charge welds quality, die life estimation, microstructure evolution during extrusion processing are some examples of the most relevant topics. He is organizer and head of ICEB, the "International Conference on Extrusion and Benchmark", which is held in Europe every two years since 2007. He coordinated and participated to several projects in the field of light alloys extrusion funded by International and National bodies as well as Companies. A full list of publications is available at http://www.unibo.it/docenti/l.donati

April 15, 2024Episode 5837 min

Anodizing Essentials - ET'24 In Conjunction Workshop

George Oh & Judy Runge join Jason Weber of the AEC to discuss their upcoming Anodizing Essentials Workshop at this years ET'24 event in Orlando. For more details visit: ET In-Conjunction Workshops | Aluminum Extruders Council (aec.org) AAC Anodizing Essentials Class 8:30 a.m. - 5:00 p.m. Fee: $495 AAC members / $895 nonmembers Instructors: AAC member anodizing experts Anodizing Essentials is part of the Aluminum Anodizers Council's (AAC) "School for Anodizers" that teaches more than the fundamentals of anodizing. This one-day class is designed to increase the knowledge and ability of anyone involved in operating an anodizing line. Anodizing Essentials Class details the foundation of quality anodizing, taking the learner through the entire process - beginning with the metallurgical properties of aluminum alloys commonly anodized through to the final rinse and sealing processes. The program is designed to benefit anodizing production personnel at every level-from the line operator to the production manager, particularly if they are new to the business. Workshop topics include: Anodizing Overview and Anodizing Video Metallurgy Basics for Aluminum Surfaces Racking Cleaning & Rinsing Etch, Desmut & Bright Dipping Anodizing Basics for Aluminum Surfaces Power - Rectifiers & Transformers for the Aluminum Surface Treatment Industry Dyeing & Electrolytic Coloring Sealing the Anodic Oxide