The combination of different materials within aluminum profiles offers significant potential for increasing the mechanical properties as well as the functionality [1]. Direct extrusion using special porthole dies which feed elements in terms of continuous wires through bridges into the aluminum base material flow, was studied to manufacture continuous reinforced profiles. To achieve an essential advantage of the technology for lightweight applications a high reinforcing volume of aluminum profiles is targeted. A comparatively high reinforcing volume can be reached either by a high number of reinforcing elements or through a reduction of the profile wall thickness. A high number of reinforcing elements leads to a small distance between the single elements in the profile cross-section. The paper will show the results of an experimental and numerical analysis carried out to determine the minimum distance between the reinforcing elements as well as the minimum allowable profile thickness. In the trials different arrangements of the elements in the profile cross-section and profile thicknesses were considered. Main parameters which have an influence on the process stability were analyzed and a process window for the manufacture of thin profiles with high reinforcing volume was deduced.