Custom plastic extrusion can create a number of products that are built to last and be effective. There are several types of different plastic extrusion processes, but the steps are largely the same with a few different nuances here and there.
Custom Profile guides you through the plastic extrusion process, while highlighting a few different benefits.
The Plastic Extrusion Process
Plastic extrusion is the blanket term for these kinds of services. There are a few specific forms of plastic extrusion that can be performed for various needs and project specifications.
But the process among the different types all starts off with one key step.
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 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.
Different Types of Plastic Extrusion Services
Custom Profile offers six varieties of plastic extrusion services.
- Profile extrusion
- Used to create long, continuous shapes with a consistent profile. Common examples include piping, sheets, and film.
- Tubing extrusion
- Custom Profile can create extruded tubes with openings as small as an eighth of an inch to three inches.
- Co-extrusion
- Used to create a plastic profile that features multiple characteristics on one single piece of plastic.
- Dual durometer co-extrusion
- A complex solution, dual durometer co-extrusion is used for creating parts that have two different materials in one piece.
- Crosshead extrusion
- This service introduces using metal where it’s encapsulated into a substrate. This process is used for creating wires, cables, pipes, and more.
- Tri-extrusion
- Through tri-extrusion, manufacturers are able to combine three different compatible polymers to make one product.
Benefits
Custom plastic extrusion offers numerous benefits as a product.
Cost-Effective
Plastic extrusion is extremely cost effective as parts are often made into a continuous shape. The larger a production run is, the more cost effective it is.
Design Flexibility
Since it is a custom part, there are multiple design flexibility considerations that can be made. The extrusion process allows for high precision shapes to be produced with minimal defects.
Material Selection
Combinations of materials or certain amounts of materials can be used during the process. Custom Profile offers over 400 different grades of polymers and over 500 color options for your custom product.
Faster Production Run
Even with a custom part, the plastic extrusion process is a faster manufacturing method compared to an injection molding service. This is largely due to the fact that extrusion production is a continuous process compared to injection molding where the mold needs to be filled and has to cool before the part is ready.
Trust Custom Profile for High-Quality Custom Plastic Extrusion Products
From the design process all the way to delivery, there should be a heightened sense of attention to detail. Custom Profile holds an ISO class 8 cleanroom certification, which allows us to handle delicate projects. While polymer profile extrusion may seem simple, this method can make hundreds of thousands of different products. Products could be delicate and this certification highlights our commitment to quality and handling throughout.
For over 30 years, Custom Profile has been an industry leader in extrusion processes and has served thousands of customers. Quality always remains at the forefront of what we do throughout our three different facilities, serving multiple markets and industries.
Custom Profile dedicated to building and delivering a product that works. For your next polymer profile extrusion project, we have the skill and the resources to get the job done. Contact us today to learn more.