Stanley Access Technologies, located in Farmington, CT, manufactures, installs, and services various automatic and manual doors. Receiving the world's first automatic door patent 90 years ago, Stanley Access Technologies has led the industry with state-of-the-art manual and automatic door solutions. Our project focuses specifically on Stanley's ProCare 8300 Series, which are human-centric ICU doors deliberately designed with respect for patients and caregivers in sensitive healthcare environments. This specific door is a two-piece aluminum extrusion including the header frame and an external cover; the price of aluminum per pound having increased by 50% since the 2020, these extrusions have increased costs on Stanley's aluminum extrusions. In this project, we have been tasked with the redesign, test, and fabrication of a new aluminum header with the goal of reducing aluminum without sacrificing sufficient strength, stiffness, and sealing. With a newly designed aluminum extrusion, cost analysis was performed to not only account for the aluminum reduction, but the resources saved in production and field installment.