Thermal Break Aluminium Window Profiles – PA66 Insulated Extrusions | Shengxin

Thermal Break Aluminium Window Profiles solve the fundamental weakness of aluminium as a window frame material: its high thermal conductivity. Solid aluminium conducts heat roughly 500 times faster than the polyamide used in our thermal breaks. By splitting the profile into interior and exterior sections and joining them with a PA66 GF25 insulation strip, we interrupt that heat path entirely. The result is a window frame that keeps heat inside in winter, outside in summer, and free from condensation all year round.

Our thermal break profiles are extruded from 6063-T5 aluminium, then precision-machined to accept the PA66 strip. The strip itself is a glass-fibre-reinforced polyamide with a thermal conductivity of just 0.30 W/m·K — compared to 160 W/m·K for aluminium. After crimping on our automated assembly line, the composite profile achieves Uf values as low as 1.8 W/m²K depending on strip width and profile geometry. Every batch is shear-tested to EN 14024 to verify the mechanical bond between aluminium and polyamide.

Shengxin has over 30 years of aluminium extrusion expertise and operates dedicated thermal break assembly lines in-house. This vertical integration gives us full control over profile tolerances, strip alignment, and finish quality. For a complete system, see our window system profiles.

Features & Benefits

• Proven thermal performance: PA66 strip widths from 14.8 mm to 34 mm achieve frame Uf values from 3.2 down to 1.8 W/m²K. The insulation effect is immediate, measurable, and permanent.
• Condensation elimination: The interior aluminium surface stays close to room temperature, preventing the moisture build-up that damages window boards, paintwork, and occupant health.
• Structural integrity maintained: The mechanical crimp bond between aluminium and PA66 is tested to EN 14024 shear strength standards, ensuring the composite profile performs as a single structural unit under wind load.
• Acoustic improvement: The polyamide strip dampens vibration transmission through the frame, contributing up to 35 dB of sound reduction when combined with appropriate glazing.
• Compatible with standard hardware: Euro-groove slots (15/20 mm) accept all major locking mechanisms and hinges. No custom hardware or adaptors required.
• Full finishing flexibility: Aluminium sections can be anodized, powder coated, or PVDF finished before thermal break assembly, ensuring a flawless surface inside and out.

PA66 Strip Width & Uf Value Reference

Select the insulation strip width that matches your target frame U-value and climate requirements.

Uf values are indicative and confirmed per project via EN ISO 10077-2 thermal simulation.

Technical Specifications

These thermal break profiles are part of our wider range of aluminum profiles for doors and windows, which includes frames, sashes, glazing beads, and reinforcement sections — all designed to work together as a system.

Applications of Thermal Break Aluminium Window Profiles

• Residential new-build and renovation: Where building energy codes mandate thermally broken frames, these profiles provide the U-values required for compliance without sacrificing the slim sightlines architects want.
• Passive House and net-zero homes: The widest PA66 strips (28–34 mm) enable frame Uf values below 2.0 W/m²K, contributing to the whole-window Uw targets required for Passive House certification.
• Cold climate and alpine regions: In areas where winter temperatures regularly drop below freezing, thermal break profiles prevent frame icing, condensation, and the associated comfort and durability problems.
• Acoustic-sensitive buildings: The PA66 strip adds measurable sound reduction, making these profiles suitable for homes near roads, railways, and airports.
• Commercial apartments and hotels: Durable, low-maintenance aluminium with thermal insulation meets the performance expectations of commercial specifiers and building managers.

Customisation & Supply Options

Why Choose Shengxin for Thermal Break Window Profiles?

A thermal break profile is only as good as the bond between aluminium and polyamide. Shengxin is an aluminium extrusion specialist with over 30 years of manufacturing experience. We extrude the aluminium sections, machine the strip channels, and perform the crimping — all in-house. This gives us complete control over the tolerance and alignment that determine both thermal performance and structural reliability.

Complete Fenestration Solutions: For curtain wall applications, see our curtain wall thermal break profiles. For standardised window series, consider our standard thermal break window series. 5 container loading platforms ensure on-time dispatch.

Thermal Break Aluminium Window Profiles FAQ

Custom Thermal Break Window Profile Solutions

Every window system has unique thermal performance targets and profile geometries. Whether you need a custom frame depth, a wider PA66 strip, or a completely new multi-chamber profile, Shengxin's custom extrusion and thermal break assembly service delivers precision profiles engineered to your exact drawings.

How It Works:

1. Send your drawing — 2D PDF/DWG or 3D STEP/IGES file showing the profile geometry and thermal performance requirements.
2. Our engineers review — we assess extrudability, thermal break placement, and provide Uf calculations.
3. Receive a quotation — including die cost, PA66 strip specification, unit price, and lead time.
4. Approve a sample — we extrude the profiles, assemble the thermal break, and send sample sections for approval.
5. Full production — consistent quality, delivered on schedule with full documentation.

⚠️ Important Note: All profile images and dimensional drawings on this page are for reference only. Final dimensions, PA66 strip specifications, Uf values, and surface finishes will be confirmed based on your approved production drawings and thermal simulations. Please contact our engineering team to discuss your specific requirements before placing an order.