The effects of different billet preparation techniques as well as selection of various deformation routes and their influence on the final mechanical properties in chip extrusion was studied. The AA6060 chips were compacted into billets using various techniques and then extruded through the flat-face, porthole and ECAP dies to create different deformation routes. The microstructures and the mechanical properties of the chip extruded profiles were compared to cast billets extruded through the flat-face die under the same conditions. The proposed technology shows very promising results in terms of energy savings and production of the high quality engineered aluminum profiles.