PLASTIC PROFILE EXTRUSION

Formtech will request the following information in order to provide a quotation:

• A drawing of the profile to quote. AutoCAD files in DXF or DWG format are preferred. Tolerances should be included on the drawing.
• Annual volume
• Estimated order quantity
• Part length(s)
• Preferred plastic resin and/or material properties desired
• Part color(s). Note that if the part is to be color matched, a sample of the color desired is required to provide the most accurate quote.
• Part appearance requirements (i.e. embossing pattern, critical aesthetic surfaces, etc.)
• Fabrication requirements with desired tolerances
• Packaging requirements
• Sample submission requirements
• Application information and/or information regarding mating parts

View our process page for more information.

Extrusion tooling costs vary depending on the complexity of the profile, tolerances, raw material, and production volume, among other characteristics. Formtech can provide the tooling cost for your profile upon receiving this information.

There are options available with custom plastic extrusions that can reduce post-extrusion processes and make getting to your end application as cost-effective and direct as possible, including:

• Multiple materials - Combine multiple function parts into one multiple material extrusion.
• Multiple colors - Use multiple colors in one extrusion, using less expensive colors in sections that are not visible.
• Hollowing an extrusion - Try to reduce weight and raw material costs by hollowing a profile without sacrificing strength, function, shape or size. 
• Select a less expensive material that can perform the same functions.  
• Utilizing inline and offline fabrication services. 

There is definitely a balance between tolerances and economics when it comes to custom profile extrusion.  To improve tolerance control, a few things can happen, however, they increase cost.  One, the output rate can be reduced in order to increase control over the extrusion cooling process.  Adding additional vacuum calibration to keep the extruded profile adds to an increased overall tool cost.  Lastly, more expensive compounds will allow better control over the plastic extrusion.  See more information regarding tolerances below.

The material that you will need will depend on the characteristics of your product and its application. Formtech can help you choose a material if we understand the following properties:

• What is the application of the product?
• How do you expect the finished profile to perform in its application?
• Will the part see any load?
• Will the part be used outdoors?
• Will the part be exposed to sunlight or UV rays?
• What temperature range will the part be exposed to?
• What are the color requirements?
• Is electrical conductivity an issue?
• Are there any regulatory requirements? (UL, NSF, USDA, FDA, etc.)

More information regarding different plastic resins is available on our materials page.

Yes, Formtech has extensive capabilities in inline and offline fabrication. Please see our services page for more information.

Formtech’s standard lead times for production orders are typically 2-4 weeks if no stocking plan is in place. Requests for expedited orders will be considered.

Formtech does build some of its own extrusion tooling.  In addition, Formtech has developed excellent relationships with tool makers across the globe, giving us additional tool building support and resources.

Plastic extrusion is a continuous process in which solid plastic pellets or powder are melted into an homogeneous mass through a combination of applied heat and friction heat generated by the extrusion screw or screws transporting the material through a barrel. The mass or polymer melt is pushed through an extrusion die to produce a shape, tube or sheet. The extrudate is then cooled by various means into its final form and cut to length using various cut-off devices.

Extrusion is a continuous process, whereas, injection molding is a discrete manufacturing process. During extrusion, the extrudate is continually produced and cut-to-length to form a part whereas, injection molding requires a cycle during which the mold is opened, filled with plastic, closed, plastic is cooled, mold opens and finished part is expelled.

Extrusion tooling consists of a die, downstream calibration, and fabrication equipment. Molten plastic enters the die at an enlarged opening that gradually narrows (much like a funnel) as the plastic nears the exit point of the die. Next, the plastic passes through a series of sizers that hold the plastic in shape until it has cooled. The shape is cut to length with a cutter or saw. Fabrication equipment, including punches or embossing rolls can be used during this process to finish the product.  View more terminology.