Plastic extrusion is arguably one of the strongest manufacturing methods to create continuous profiles that feature a cross section with tight tolerances. But what if your projects needs something a little more?
Consider plastic crosshead extrusion services. This operation involves encapsulating a piece of metal or wire in a substrate. Organizations typically pursue this manufacturing method to create wires, cables, pipes, and more.
Follow Custom Profile’s comprehensive guide covering the ins-and-outs of manufacturing, best applications, and key benefits.
Differences in the Manufacturing Process Between Crosshead Extrusion and Traditional Extrusion
There aren’t many major differences between traditional plastic extrusion and plastic crosshead extrusion services. Both utilize common thermoplastics such as polyvinyl chloride, polyethylene, and polypropylene. Both require tooling operations to create dies and both services can feature secondary operations at the end of manufacturing. Where the differences lie occur in a few places.
- In crosshead extrusion, rather than creating a solid independent shape, this form of extrusion necessitates a continuous core material being fed into the die. This is the non-plastic component, usually a metal structure.
- Tooling is more focused on introducing and stabilizing the core so the molten plastic flows around the core without creating damage and defects.
- The molten plastic is fed into the crosshead die at a 90-degree angle instead of a linear path compared to traditional extrusion.
- While more focused on the application sections below, crosshead extrusion is geared toward electrical applications or where products need reinforced capabilities within tubes.
Common Applications of Plastic Crosshead Extrusion Services
OEMs and other customers in contract for plastic crosshead extrusion services often rely on these services when they or their customers need parts that feature continuous structural reinforcement at a cost-effective measure or a functional core.
- Cable and wire jacketing
- Reinforced tubes
- Gaskets and seals featuring embedded metal
- Structural profiles
Key Benefits
Like other extrusion operations, crosshead extrusion does benefit from continuous shapes and profiles and cost-efficient measures, but there’s more at stake.
- Crosshead extrusion’s main aspect of integrating metal inserts for a stronger, more versatile product eliminates the need for secondary services such as bonding, clipping, or using fasteners for assembly.
- Even with the additional materials needed for crosshead extrusion, it’s still a cost-effective manufacturing service where high-volume manufacturing takes place. This all stems from once tooling costs have been offset.
- While there are more materials used, waste is still low compared to other plastic manufacturing services and majority of that scrap can be reused and reprocessed.
- One of the largest benefits of crosshead extrusion, and by extension extrusion services in general, is the dimensional consistency of products that’s caused by the cross-sectional tolerance within a production run.
- Wall thickness specifically in crosshead extrusion applications where wire or strips are featured can be controlled by well designed tooling as well as process control.
Partner With Custom Profile for Your Plastic Crosshead Extrusion Services Today
Custom Profile has provided expert plastic extrusion solutions to OEMs and countless other customers since our inception back in 1992. Headquartered in Grand Rapids, Michigan, but with facilities also in Camden, South Carolina, and in Mexico, we’re able to perform the high-level extrusion operations your team needs and can reach any destination.