Understanding the steps of the plastic extrusion process helps customers expand their knowledge of their product and find a quality manufacturing company to partner with.
Let’s break down the process from start to finish, while addressing some common questions along the way.
Plastic Extrusion Process: The Steps
Material Selection and Preparation
Materials are selected based on the product’s intended use, desired properties, and required applications.
Once the materials have been selected, they are placed into a hopper in the form of resin. The hopper holds and stores unprocessed materials while continuing to feed the resin into the extruder.
Melting
As the resin begins to flow from the hopper into the extruder, it’s time for your project to move into the melting phase. The extruder heats up the resin to its melting point using a heated barrel and rotating screw.
Shaping
When the material has melted it moves into the shaping step, also known as formation. The melted material continues to move, only this time it is out of the extruder and into a die.
This is arguably the most critical point of the plastic extrusion process. In this step, the product gets made into its desired shape through the die, which means consistency and continuity of the shape are essential. This is where the design portion comes to life and, if there are any inaccuracies with the physical product, the first step is to revisit the design.
Cooling
Once the product has taken shape, it’s ready to be cooled. This can happen in a variety of ways, but the two most common are through air chilling or water cooling. Controlled rate of cooling is essential because any changes in temperature could result in a product defect.
Finishing
Any final details your product might need take place in this last step before it is ready to ship out. Common customer modifications include cutting or drilling for other pieces to fit, depending on what the plastic extruded piece is used for.
Considerations for a Quality Plastic Extrusion Process
Production Time
Using plastic extrusion, production time may vary drastically depending on order size. Because of the process and steps involved, there’s going to be a higher attention to detail. One misstep in the extrusion process could lead to product defects and result in a rerun, which can be costly.
This is why it’s important to work with a manufacturer that can handle the process from design through finishing. It leads to less errors and defects, making the process more cost-effective.
Materials Used
Picking the right material is critical, and the manufacturer should know which to used based on the product. A few examples include:
- Polyethylene: PVC pipes
- Polypropylene: Packing and automotive materials
- Polyvinyl chloride: Window frames, pipes, and wire insulation
A Common Misconception
It’s important to note that plastic extrusion and polymer extrusion aren’t exactly the same thing. While the terms are often used interchangeably, plastic extrusion is a specific type of extrusion, while polymer extrusion is the broad term.
Plastic is a type of synthetic polymer, but polymers themselves include both synthetic and natural materials that hold defined molecular properties.
How to Find the Right Manufacturer
Above all else, finding the right manufacturer sets the tone for everything else. The right manufacturer is going to have processes in place that streamline production and make things easy for you.
Here at Custom Profile, that’s how we operate.
For over 30 years, we’ve been an industry leader in all types of polymer extrusion services. We hold an ISO Class 8 cleanroom certification, which allows us to handle delicate projects.
As plastic experts, Custom Profile offers a variety of services, including plastic extrusion, assembly, finishing, materials selection, and more. If you need help with a future plastic project, connect with us today. Interested in reading more about plastic manufacturing? Click here to explore our blog.