Denver Zoo Australia Exhibit: A TIG-Welded 6063 Aluminium Cassowary Enclosure
For Denver Zoo’s Australia exhibit, TCB Metal Works engineered and built a secure enclosure for the cassowary — one of the most powerful birds in the world — crafted entirely from TIG-welded 6063 aluminium and designed to balance maximum visitor visibility with barrier strength.
The Denver Zoo Cassowary Enclosure
A leading accredited zoo and conservation institution.
Fabricated in Racine, WI for the zoo's Australia exhibit.
A large, powerful ratite requiring high-security containment.
Crafted entirely from 6063 aluminium — corrosion-resistant and formable.
Precision TIG-welded for strong, clean, durable joints.
From structural design through fabrication.
Containing One of the World’s Most Powerful Birds
A cassowary is not a typical exhibit animal. Standing up to six feet tall with dense, powerful legs and a dagger-like inner claw, it is widely considered one of the most dangerous birds to house. An enclosure for one has to hold up to real force while keeping keepers, the public, and the animal safe.
The Australia exhibit also demanded more than raw strength. The enclosure had to resist corrosion outdoors, give visitors clear sightlines into the habitat, and blend seamlessly into the exhibit's natural surroundings — all without compromising containment.
That combination — security, durability, visibility, and clean visual integration — is exactly the kind of one-off, get-it-right-the-first-time problem TCB is built for.
Engineered Aluminium Containment, Built to Institutional Standards
We designed the enclosure around the animal — its strength and behaviour — and around the exhibit, then fabricated it to hold up for the long term.
- 6063 aluminium construction — the enclosure was crafted entirely from 6063 aluminium, chosen for its corrosion resistance and formability.
- Precision TIG welding — meticulously TIG-welded for strong, clean joints that withstand the elements and the test of time.
- Balanced open design — an optimal balance of open space and barrier strength, for maximum visibility without compromising safety.
- Blends with the exhibit — a lightweight, natural-looking structure that blends seamlessly with the exhibit's surroundings.
- Corrosion-resistant, low-maintenance — 6063 aluminium resists corrosion without coatings, for a lightweight yet sturdy structure.
Why 6063 Aluminium
6063 aluminium gives a rare combination: it resists corrosion without coatings, stays light enough to work with in large spans, and — when TIG-welded — forms joints that are both clean-looking and genuinely strong. That means a lightweight yet sturdy structure that holds its integrity for years with minimal upkeep.
Fabricated entirely from the one material and TIG-welded throughout, the enclosure works as a single engineered system — not parts bolted together — designed specifically for the cassowary and the exhibit it sits in.
Request a ConsultationA Secure, Durable Exhibit That Performs
The finished enclosure meets the zoo’s containment and safety requirements while standing up to daily use.
Safe Containment
High-security containment engineered specifically for a cassowary’s strength and behaviour.
Maximum Visibility
An optimal balance of open space and barrier strength keeps the habitat visible for visitors.
Built to Last
Corrosion-resistant 6063 aluminium designed for a long service life with low maintenance.
Institution-Grade
Fabricated to the standards an accredited zoo exhibit demands.
Planning a Zoo Exhibit or Enclosure?
Tell us about the species and the setting. Our specialists will help you scope, engineer, and fabricate secure, durable containment built to institutional standards.