Aluminium Window Fabrication Machine Setup Guide for a New Workshop

Setting up an aluminium window fabrication workshop takes six machines and a compressor. You need a cutting machine, an end milling machine, a copy router, a punching machine, a pillar drill and an air compressor for the pneumatic machines. This guide explains what each machine does, the order of work on a window frame, and how to choose between manual and pneumatic models.

Mechnovate manufactures the cutting machine, end milling machine, copy router and punching machine in Ahmedabad. We do not manufacture the pillar drill or the compressor, but we supply both with your order so you can buy the whole setup from one place.

The machines in an aluminium window workshop

Machine	What it does	Made by Mechnovate?
Cutting machine	Cuts profiles to length at 45° or 90°	Yes
End milling machine	Shapes mullion and transom ends so T-joints close without gaps	Yes
Copy router	Routes lock, handle and drainage slots using a template	Yes
Punching machine	Punches cleat holes, interlock slots, drainage slots and hardware holes	Yes
Pillar drill	Drills screw and fixing holes	Supplied, not manufactured by us
Air compressor	Supplies compressed air to pneumatic machines at 6–8 bar	Supplied, not manufactured by us

The order of work on a window frame

1. Cut. Every profile is cut to length first. A 14 inch aluminium cutting machine with pneumatic clamping gives square, burr-free 45° mitre and 90° straight cuts.
2. Mill the ends. Mullions and transoms that meet another member are shaped on the end milling machine so the T-joint closes tight.
3. Route. Lock, handle and drainage slots are routed on a manual copy router or a pneumatic copy router. A template guides the cutter, so every frame is identical.
4. Punch. Cleat holes, interlock slots and drainage holes are punched next. The manual punching machine handles cleat punching and interlock punching with the matching die, and the two station pneumatic punching machine punches two patterns without changing dies.
5. Drill. Screw and fixing holes are drilled on the pillar drill.
6. Assemble and glaze. Corner cleats, gaskets and glass go in at the assembly bench.

Manual or pneumatic?

• Manual machines need no compressor and cost less. They suit start-ups, small workshops and site work.
• Pneumatic machines are faster and less tiring because air does the clamping and punching. They suit workshops that make many windows a day.

A common path is to start with manual machines and add pneumatic ones as orders grow. Copy router templates work on both the manual and the pneumatic model, so nothing you set up is wasted.

Choosing the compressor

Pneumatic machines run on compressed air at 6–8 bar. The right compressor depends on how many pneumatic machines run at the same time. Tell us which machines you plan to buy and we will recommend and supply a compressor that suits them.

Workshop space and power

• Allow clear floor space around the cutting machine for long profiles. A cut profile needs room on both sides.
• Keep the copy router, punching machine and pillar drill near each other. A frame member moves between them.
• The cutting and end milling machines are available for single-phase or three-phase power, so you do not need to upgrade your supply for them.

What to share to get a quotation

• The profile systems you will work with.
• How many windows you plan to make per day.
• Whether you need manual or pneumatic machines, or a mix.
• Whether you want us to supply the pillar drill and compressor.

Send these on the quotation form or call +91-9265699061 and we will propose a setup with a written quotation. For a deeper plan on layout and budget, read our workshop setup guide.

Frequently asked questions

What machines do I need to start an aluminium window workshop? A cutting machine, an end milling machine, a copy router, a punching machine and a pillar drill, plus a compressor if you choose pneumatic machines.

Do you make the pillar drill and compressor? No. We manufacture the cutting, end milling, copy router and punching machines. We supply the pillar drill and compressor so you can order the full setup together.

Can one punching machine do cleat and interlock punching? Yes. The manual punching machine does cleat punching and interlock punching on aluminium profiles with the die made for your section.

Can I start with manual machines and upgrade later? Yes. Copy router templates are the same on the manual and pneumatic models, so you can move to pneumatic without redoing your templates.