Aluminum alloysAluminum alloy from the Al–Mg–Si system, particularly 6005 and 6082, are widely used in automotiveAutomotive structural applications due to their balanced combination of strengthStrength, formabilityFormability, and corrosion resistance. This study focuses on evaluating the mechanical performance and bendability of extruded aluminumAluminum profilesProfile to explore alternatives to welded assemblies in structural components. Tensile, bending, and compression tests were performed, supported by finite elementFinite element simulationsSimulation, to assess the strengthStrength and deformation behavior of both alloys. The results show a strong correlation between experimental and numerical findings, validating the simulationSimulation model for predicting crush performance. While direct welding experiments were not conducted, the findings demonstrate that bending can effectively achieve the required geometries without introducing the strengthStrength reduction, additional mass, and cost typically associated with welding. Furthermore, the influence of alloy composition and extrusionExtrusion parameters on strengthStrength and formabilityFormability was analyzed, providing insights into optimizing extrusionExtrusion-based forming routes for lightweightLightweight and crashworthy automotiveAutomotive structures.