When homeowners in Leawood, Olathe, or Overland Park start shopping for new windows, they often hear the terms “extruded aluminum” and “roll formed aluminum.” Both sound similar, but they are very different in how they’re made and how they perform in our unpredictable Midwest weather.
We’ve installed and replaced thousands of aluminum windows since 1996, and we want to give you a clear, no-fluff breakdown so you can make the right choice for your home.
Extruded aluminum is made by forcing molten aluminum through a die under high pressure. Think of it like pushing Play-Doh through a shaped hole — you get a very strong, dense, uniform frame. This process allows for thicker walls and more complex shapes.
Roll formed aluminum is made by taking flat sheets of aluminum and rolling them through machines that bend and shape them into frames. It’s faster and cheaper to produce, but the resulting frame is thinner and less rigid.
Both types of aluminum windows share some big advantages:
Here’s where they really separate — especially with our wild temperature swings, high winds, and storms:
Strength & Durability
Extruded aluminum is significantly stronger and more rigid. It handles high winds, hail, and temperature changes much better. Roll formed aluminum is lighter and more flexible, which means it can dent or bow more easily during a strong thunderstorm or ice storm.
Thermal Performance
Neither is naturally a great insulator (aluminum conducts heat and cold), but modern extruded aluminum windows (like Marvin’s) usually come with a thermal break — a plastic or polymer strip that stops heat/cold from transferring through the frame. This makes them far more energy-efficient in Kansas City’s extreme winters and summers. Roll formed frames are thinner and rarely have a true thermal break, so they can feel colder in winter and transfer more heat in summer.
Cost
Roll formed aluminum is usually the more budget-friendly option. Extruded aluminum costs more upfront but typically lasts longer and performs better over time in our climate.
Marvin’s Approach
Marvin almost exclusively uses extruded aluminum in their premium lines (Signature Ultimate, Elevate, and Modern). They add a thermal break and pair it with high-performance glass, making these some of the best-performing aluminum windows we install in Leawood and Olathe homes.
Andersen and Pella
Andersen uses extruded aluminum in many of their higher-end products, while Pella offers both — their Impervia line uses a fiberglass/aluminum hybrid that performs very well in our area.
If you want maximum strength, better energy efficiency, and long-term performance in our Midwest weather, go with **extruded aluminum** (especially Marvin’s thermally broken systems). It’s worth the extra investment for most homes in Leawood, Olathe, and the surrounding areas.
Roll formed aluminum can be a good, more affordable choice for smaller projects or less demanding areas, but we generally recommend it less often in Kansas City because of how much our weather stresses the frames over time.
Not sure which is right for your house? We’ve installed both types in every kind of home — from historic Mission Hills houses to new builds in Olathe. Text or call us at 913-944-0488 or fill out the form on our site. We’ll come out, measure, and give you straight talk and a free quote. No pressure, just honest advice based on what actually performs best here.
What kind of windows are you thinking about? Drop a comment or give us a shout — we’re here to help Kansas City homeowners get it right.