A strong extrusion design is the first step toward creating a product that’s built to last. Over the years, Custom Profile has seen what a strong, thorough design can do for our customers’ products in numerous industries.
While there isn’t a one-size-fits-all solution to ensuring designs are sound, our guide on how to enhance your extrusion design is a starting point.
Extrusion Design Starts With Attention to Cross-Sections
The first point to focus on in extrusion design is the cross-sections. These are what give the product its shape, and there are a few points to consider during the design process.
- Keep walls as uniform as possible. This allows for consistency, even flow, and uniform cooling during extrusion.
- Uniform walls also prevent defects such as bowing and profile distortion.
- The more symmetrical the cross-sections are, the better. This reduces die deflection, improves straightness, and stabilizes hollow sections.
Keep Tabs on Hollow Sections and Internal Aspects
Extruded hollow profiles are naturally going to have hollow sections per design, which is why it is critical to focus on those portions as well as internal aspects during the design phase.
- The less detail in hollow sections, the better, to maintain internal definition and consistency throughout the design.
Considerations for Wall Thickness, Radii, and Transitions
Wall thickness, radii, and transitions are all related and work with one another, but they aren’t interchangeable concepts. Keep these points in mind while drafting up your extrusion design.
- Teams should allow for excess corner radii to ensure smooth material flow, prevent stress considerations, reduce die wear, minimize defects such as cracking, and improve overall strength and quality.
- Anywhere a thick-to-thin transition appears, streamline the transition by using gradual tapers and proper radii to minimize potential defects such as sink and uneven flow.
Tolerances and Length in Extrusion Design
Tight tolerances are always a talking point in any manufacturing service, and extrusion is no different. But here are a few expert points about tolerances and length to make note of.
- Consider length and feature tolerances. Thermoplastics expand and contract significantly throughout the extrusion process, so design these aspects with the material in mind.
Material Selection Meets Design
Design and material selection are two of the most important aspects of the extrusion process, and go hand-in-hand when planning the project.
- Design for manufacturability, and that includes considerations for your material selection. Materials all contain different properties, strengths, and weaknesses. Ensure your design maximizes the strengths and minimizes the weaknesses.
Have Extrusion Design Questions? Contact the Expert Team at Custom Profile Today
Custom Profile has been an industry-leading extrusion manufacturer since our inception back in 1992. For over 30 years, we’ve poured resources, time, effort, and hard work into understanding the finer points of extrusion design, ensuring your products work as designed.
We offer multiple capabilities available at all three of our locations.
Have further questions about how to enhance your design, or have a design ready to go? Contact us today, and we’ll set up a time to review the design and get started on your project.