Based in Milwaukee, WI, Absolute Custom Extrusions, Inc. provides custom plastic extrusion services for industrial clients. Leveraging over 40 years of experience, they tailor extrusions using various materials and tooling. The company serves industries including sporting goods and manufactures poly straw products.
Need a specific city or state? Want to email them directly?
Search, get contacts, and send outreach — all in one place.
Plastic Extrusion Companies
Last updated: January 2026
This directory lists 83 plastic extrusion companies across the United States, from specialized niche providers to full-service manufacturers.
Buyers in this category frequently grapple with ensuring dimensional stability, achieving tight tolerances on intricate profile geometries, and effectively managing the unpredictable nature of die swell. Beyond basic shape, challenges often involve consistent material properties, surface finish, and the integration of secondary operations all within a repeatable process.
The landscape of plastic extrusion suppliers is varied, ranging from high-volume commodity extruders focused on standard shapes to highly specialized custom profile houses. Some excel in co-extrusion, combining different materials or colors in a single pass, while others differentiate themselves with extensive in-house downstream tooling capabilities for punching, drilling, or notching.
To secure an accurate quote and ensure project success, buyers should come prepared with detailed CAD drawings (ideally with GD&T callouts), precise material specifications (including specific resin grade and manufacturer if applicable), estimated annual volumes, and any critical dimensions or surface finish requirements. Suppliers expect a clear understanding of the application and performance expectations.
A significant trend reshaping the plastic extrusion sector is the escalating demand for sustainable materials, including bio-based polymers and recycled content. Simultaneously, there's a push for greater integration of smart manufacturing and real-time process control, enhancing efficiency and enabling more complex multi-material co-extrusion for advanced functional properties.
Company Directory
83 companies nationwide
Based in Anaheim, CA, Anaheim Custom Extruders, Inc. specializes in custom thermoplastic extrusions. They manufacture tubes, rods, and profiles from over twenty engineering and commodity resins, handling orders from prototype to millions of feet. The company offers in-house engineering, tool design, and fabrication for cut lengths, drilling, and punching.
Based in Rogers, MN, Advanced Extrusion, Inc. specializes in close tolerance plastic extrusion. They produce custom polyester roll stock, including APET, RPET, CPET, and CPLA, for the thermoforming and laminating industries. Capabilities include up to 7-layer coextrusion.
Based in Paterson, NJ, All American Extrusion specializes in custom plastic profile extrusion services. The company offers expert product engineering, in-house tool design, fabrication, and assembly solutions. They focus on precision and innovation to meet unique customer requirements for diverse plastic profile needs, including drop shipping.
Based in St. Louis, MI, Alpha Extrusions specializes in custom plastic extrusion services, offering precision fabrication and profile extrusions. They provide a wide range of capabilities for various industries, including plastic CNC fabrication, plastic sheet cutting, and sonic welding services, leveraging years of expertise.
Based in Minneapolis, MN, Astro Plastics designs and manufactures OEM and custom profile extrusions. They produce thermoplastic, dual, and tri-extrusions, offering weatherization solutions for building, marine, lighting, and various commercial markets. The company creates cost-effective plastic products to enhance overall quality and performance.
Based in Milford Center, OH, Advanced Technology Products (ATP) manufactures and distributes plastic tubing, hose, and industrial accessories. Established in 1990, the company initially focused on polyurethane spiral recoil hoses for the Japanese automotive industry, and has expanded its product offerings.
Based in Bristol, IN, BD Custom Manufacturing specializes in custom plastic profile extrusions. The company provides extruded plastic solutions for small and medium-sized businesses, forming solid or hollow profiles. They offer over 100 custom colors and 500 custom profiles, using over 10 different materials.
California Industrial Rubber Company manufactures custom PVC extruded profiles in-house using virgin raw materials. They produce T Cleats, Scoop Cleats, and V-guides for fabricated belting. These PVC products offer excellent fastener-holding strength and withstand high tensions, ensuring smooth conveyor operations in the U.S.
Based in St. Louis, MO, Clark Rubber & Plastic provides custom plastic extrusion services. The company specializes in producing profiles, shapes, and forms with varying thicknesses, hardnesses, colors, and textures. They offer custom dies and tooling, delivering high-quality extruded plastic products to meet specific client specifications.
Control Plastics provides custom plastic extrusion solutions from its Menlo Park, CA facilities. They produce high-quality profiles, tubing, and complex shapes from various thermoplastics. Serving construction, medical, and automotive industries, the company also offers secondary operations like machining, welding, and finishing.
Based in Northville, MI, Cooper Standard specializes in providing custom plastic seals for diverse industries. The company's engineers design and optimize seal solutions from start to finish, delivering tailored components to meet specific client specifications, focusing on robust and effective plastic sealing products.
Based in Painesville, Ohio, Extrudex is a plastic extrusion company with over 35 years of experience in various extrusion technologies. They specialize in custom engineered thermoplastic components, offering custom profile extrusions, tubing, and hose capabilities. Extrudex also produces proprietary FleX-J channels for diverse customer needs.
Fukuvi USA, Inc. is a Huber Heights, OH-based plastic profile extruder specializing in tight tolerances and advanced coextrusion techniques. The company offers onsite processing and fabrication capabilities, partnering with customers for optimal product form, fit, and function using a wide variety of plastic raw materials.
Green Eagle specializes in manufacturing custom plastic extrusions and profiles. The company develops tailored solutions for diverse applications, offering expertise in various plastic materials and design specifications. They focus on delivering precision-engineered components to meet specific client requirements.
Based in Strongsville, OH, GSH Industries specializes in custom plastic extrusions, transforming raw materials into precise, high-performance shapes. The company offers design, engineering, and tooling services, utilizing state-of-the-art technology to create high-quality products that meet exact specifications for various applications.
Based in Irvine, CA, Impact Catheters provides plastic extrusion services primarily for medical product needs. They specialize in manufacturing complex tubing and components from engineered thermoplastics, offering custom die and tip design. Additional services include catheter tipping, extrusion setup, and equipment repair.
Based in Naperville, IL, Inplex LLC provides custom plastic extrusion services, manufacturing tubing and profiles. They also offer plastic coating and jacketing. Working with diverse engineering and commodity plastics like ABS, Kynar, and PE, the company serves industries such as consumer housewares, lighting, and electrical utilities.
Based in Hastings, MN, Intek Plastics, LLC. provides custom plastic extrusion and injection molding solutions. They deliver precisely engineered, customer-specific extrusion products, including complex profiles, co-extrusions, and multi-material configurations. The company utilizes advanced capabilities to support a wide range of materials from prototype to production.
Based in Los Angeles, CA, Jet Plastics specializes in custom plastic profile extrusion, injection molding, and fabrication. Established in 1948, they offer comprehensive capabilities including in-house tool making and secondary operations. Serving various industries, Jet Plastics provides custom plastic components tailored to specific requirements.
Based in Sheboygan Falls, WI, Jifram Extrusions, Inc. provides custom plastic extrusion profiles, channels, and extruded PVC tubing. The company offers manufacturing with custom or in-house tooling, prototyping, secondary operations, and fulfillment services. Serving POP and OEM markets, products are manufactured in the U.S.A. since 1981.
Based in Aurora, OH, Lerner Molded Plastics provides custom plastic extrusion services. They specialize in single, co, and tri-extruded profiles, pipes, and tubes up to 12 inches. Serving OEM, automotive, and consumer industries, their ISO certified facility offers food-grade and flame-retardant solutions for varied production volumes.
Based in Middlefield, OH, Mercury Plastics LLC offers innovative thermoplastic profile extrusion, injection overmolding, and custom fabrication. They specialize in PFAS-free manufacturing for diverse markets, including appliance, automotive, and medical. Mercury Plastics also operates a unique captive electron beam processing facility for internal products and external customers.
Based in Arlington, TX, Ranger Plastic Extrusions, Inc. specializes in custom plastic profile extrusions. Their professional engineering staff assists in designing products to meet specific needs, guaranteeing effective solutions. The company offers quick and cost-effective delivery throughout the United States.
Based in Pasadena, TX, Modern Polymer Pipe & Extrusions provides high-performance HDPE pipe and profile extrusion services. The company specializes in HDPE 4710 poly pipe, producing diameters from 2-inch to 24-inch. They serve diverse industries like oil and gas, agriculture, and power generation, offering NSF-certified products.
Based in Montebello, CA, Montebello Plastics manufactures high-quality polyethylene film. The company specializes in extrusion solutions using LDPE, HDPE, PCR, and specialty plastics. With over 40 years of experience, they provide customizable film products for various manufacturing and industrial applications.
Montville Plastics & Rubber, based in Parkman, OH, provides custom plastic extrusion and injection molding. They offer complete product development, from design, engineering, and prototyping to tooling and final production. Specializing in material selection, they serve diverse markets including automotive, construction, electrical, and consumer products with value-added services.
M&P Manufacturing USA provides plastic extrusion services, handling complex jobs like thin wall, co-extrusion, and ultra-precision solutions. They work with plastics such as PVC, polyethylene, polypropylene, and acrylic. The company serves various industries, including automotive, medical, and telecommunications, managing short to large-run projects from domestic facilities.
Based in Odessa, TX, Orrex Plastics Company specializes exclusively in reactive extrusion compounding. Their services include functionalization, neutralization, viscosity modification, and vulcanization, often combined in single extrusion step processes. The company provides complex compounding and plastics processing capabilities for various applications.
Based in Columbus, OH, OSI Plastics, founded in 1975, provides plastic extrusion and structural steel fabrication services. The company offers full-service contract manufacturing for plastic and steel products, specializing in pipe and custom plastic profile extrusion from concept to production.
PBS Plastics specializes in custom industrial extrusions, providing durable and high-quality solutions for diverse manufacturing needs. Based in Barrington, NH, the company offers precision engineering to meet specific client requirements. They focus on delivering reliable plastic components for various industrial applications.
Based in Middlesex, NJ, Petro Extrusion Tech., Inc. specializes in custom plastic extrusion and offers various stock products. Capabilities include in-line cutting, tape application, coiling, angle cutting, and customized lengths. They provide NylaGlide™ GR channels, PVDF tubing, and Acrylic Profiles for applications like Point of Purchase (POP) displays.
Based in Cranford, NJ, Petro Packaging Company Inc. provides custom plastic extrusion services. The company specializes in manufacturing a variety of plastic products, including tubes, containers, and custom profile extrusions. They also offer injection molding capabilities to serve diverse applications.
Based in Riverside, CA, Plastic Extrusion Company manufactures custom plastic sheet and rollstock. They specialize in materials like ABS, HMWPE, ASA, and PPFR. Serving thermoformers, fabricators, and screen printers, the company offers color matching and stock materials to meet specific client needs.
Based in North Ridgeville, OH, Plextrusions Inc. offers custom extruded plastic products and parts. Capabilities include profile, tubing, co-extrusion, tri-extrusion, embossing, and custom colors. They process flexible and rigid PVC, polypropylene, polyethylene, and ABS, serving diverse markets like automotive, marine, construction, and residential.
Based in Ontario, CA, Poly Extrusions Inc. provides custom plastic extrusion, tubing, and profiles with over 35 years of experience. They specialize in plastic extrusion die development and offer value-added inline processes, designing products to reflect specific customer needs.
Based in Chesterfield, MI, Profile Manufacturing, Inc. produces custom co-extruded, dual durometer, and straight profile plastic components. They design extrusion dies, offering secondary operations including end cap, die cut, and heat forming. Serving automotive, marine, and construction industries, the company is IATF 16949:2016 Certified.
Based in Canton, OH, Profile Plastics, Inc. specializes in custom plastic extrusion services. They provide custom profile, coextrusion, and cross head extrusion, manufacturing diverse profiles. The company integrates features like hinges, seals, and reinforcement. Value-added services include fabrication, assembly, and custom packaging, translating designs into finished products.
Based in Dayville, CT, Putnam Plastics Corporation specializes in medical catheter extrusions and minimally invasive tubing. The company offers a wide range of extrusion technologies for medical devices, utilizing continuous manufacturing processes. They provide complex composite catheter designs, serving the medical device industry.
Based in Arlington, TX, SantopSeal manufactures custom extruded TPE/TPV parts, specializing in Santoprene extrusion. They produce products like gaskets, O-rings, cord, tubing, and seals. The company also provides custom die-cut gaskets and makes general and food-grade Santoprene tubes, including peristaltic tubes.
SeaGate Plastics, with facilities in Ohio and Michigan, specializes in custom and standard plastic extrusion, injection molding, and CNC machining. They offer comprehensive plastic fabrication, assembly, and in-house tooling. Serving industrial, packaging, construction, and OEM customers, the company has manufactured components since 1987.
Based in St. Louis, MO, Seiler Plastics specializes in custom plastic extrusion. The company provides high-quality extruded plastic components and profiles, serving clients across various industries in the United States.
Based in Cadott, WI, SFR Industries manufactures custom plastic profile extrusions. The company serves diverse sectors including furniture, store fixtures, and original equipment manufacturers. They specialize in unique custom profile extrusion requirements, employing thermoplastic raw materials and a precise shaping, sizing, and cooling process for ongoing consistency.
Based in San Diego, CA, Trans-Continental Manufacturing (TCM) specializes in custom plastic profiles, single and multi-lumen tubing, and rod. They extrude a wide selection of thermoplastic materials like PVC, PE, ABS, and Nylon. Capabilities include micro-extrusions, co-extrusion, crosshead extrusion, cutting, coiling, and punching for various demanding applications.
Based in Fort Worth, Texas, Thermo Plastics Corporation is a custom plastic extrusion company. They specialize in window and door profiles, POP components, aerospace, military, oil and gas, and electronics industries. Capabilities include rigid and flexible polymers, co-extrusion, and an in-house tool room with EDM and CNC machines.
Toray Plastics (America), Inc., located in North Kingstown, RI, manufactures high-performance plastic films and foams. They utilize extrusion processes to produce OPP and PET films, along with various extrusion-coated foams. These materials serve packaging, automotive, and engineering applications.
Ultrafab, Inc. is a custom plastic profile extrusion manufacturer headquartered in Farmington, NY, with several US manufacturing locations. The company specializes in sealing products for the fenestration industry, offering custom plastic extrusion design solutions through dedicated research and development efforts.
Based in La Habra, CA, Vip Rubber & Plastic specializes in custom plastic extrusions and fabrication. They manufacture plastic seals for doors and windows, weatherstripping, and plastic pipe and tubing. The company has been producing high-quality parts in the USA since 1961.
Based in Arnold, MO, VisiPak specializes in plastic extrusion, creating continuous profiles such as clear plastic tubing. They extrude materials like PETG, PET, and propionate into various shapes including round, square, and triangular. The company also offers engineering, design, and prototyping services.
Vytron LLC provides custom thermoplastic extrusions and specialty fabrication support. They specialize in single, co, and tri-extrusion profiles. The company operates 23 extruders, capable of co-extruding materials, offering high-capacity output for diverse industries from its US facilities.
Based in Houston, TX, Blackwell Plastics LP specializes in custom plastic injection molding and plastic extrusion. The company manufactures engineering grade thermoplastic resins for demanding industrial applications. They serve sectors including Life Sciences, Industrial, and Energy, offering in-house plastic extrusion die building, machining, and assembly services.
Based in Oceanside, CA, Calpex Plastics Inc. is a custom manufacturer of plastic extrusions. They produce tubing, pipes, profiles, rods, spiral wrap, coils, and 3D printing filaments, serving industries such as automotive, electronics, packaging, water filtration, irrigation, and construction with quality extruded products.
Based in Bad Axe, MI, Gemini Group provides engineered plastics profile extrusion and co-extrusion services through its divisions. They specialize in complex profiles, utilizing specialty materials for demanding applications. Capabilities include tooling design, prototyping, production processing, and secondary operations for industries like automotive, building and construction, and agriculture.
Advanced Drainage Systems manufactures durable plastic pipe and innovative stormwater management solutions. They provide a comprehensive suite of high-performing products, including dual wall pipe, fittings, and various drainage structures. The company specializes in advancing water infrastructure for commercial, residential, and agricultural applications.
Alliance Plastics Corp., based in Chippewa Falls, WI, specializes in custom plastic extrusion profiles. The company offers precise tolerances and specialized finishes, delivering products for various industries. Their team guides projects from initial concept through tooling production to final product delivery.
Berlin Plastics, based in Millersburg, OH, provides custom plastic extrusion services. They extrude custom profiles using Polyethylene and PVC for manufacturers and wholesalers in consumer, windows, and door markets. Capabilities include sling spline, garage door guides, HDPE lumber, and PVC weatherstripping, meeting diverse application needs.
Based in Irvine, CA, CA Sealing Solutions manufactures custom plastic profile extrusion products. They provide design engineering, in-house tooling, full manufacturing capabilities, and in-line and offline fabrication services. The company offers stock profiles and custom solutions, utilizing 3D printing for prototypes.
Confluent Medical Technologies specializes in custom medical extrusions for the medical device industry. They develop complex configurations, including multi-lumen and tri-layer tubing. The company works with thermoplastics like PEBAX, Nylon, and Polyurethane, producing tubing with outer diameters from 0.010″ to 0.500″.
Based in Birmingham, AL, Consolidated Pipe & Supply manufactures and fabricates piping, fittings, and valves. They produce PVC pipe for the sewer and water industries nationwide, and design and fabricate HDPE products from facilities in Georgia and Idaho. The company serves energy, oil & gas, and utility sectors.
Based in Mesquite, TX, Dallas Plastics specializes in blown film extrusion, utilizing monolayer and co-extrusion processes for various plastic films. Capabilities include custom color, resin blends, and multi-layer coextrusion. They manufacture products like bags, liners, and polyethylene sheeting for medical, food, and industrial sectors.
Based in Columbus, OH, Engineered Profiles offers custom plastic extrusion services for original equipment manufacturers. Capabilities include multi-core extrusion, in-house tooling, and custom finishing operations. They design and deliver custom extruded solutions for industries such as agriculture, building products, energy, and HVAC.
Based in Hagerstown, MD, Fabricated Extrusion Company offers custom plastic extrusion services, including profile, sheet, and coextrusion. They work with engineered resins, ensuring precise tolerances and rapid response. As a turnkey manufacturing partner, Fabexco also provides injection molding, custom tooling, design engineering, and adaptable finishing operations.
Based in Eau Claire, WI, Five-Star Plastics specializes in custom plastic extrusions, offering profile, co-extrusion, tri-extrusion, and quad-extrusion capabilities. They provide expertise in material selection, matching tough, durable, and flexible options to project requirements like impact resistance or weatherability. Services also include plastic injection molding.
Based in McMinnville, OR, Freelin-Wade Co. manufactures wholesale and custom plastic tubing. They offer products in Nylon, Polyethylene, Polyurethane, and PVC, focusing on high-quality production and fast shipping. The company also provides accessories like fittings and tube cutters to complement their tubing offerings.
Based in Hudson, OH, Hudson Extrusions Inc. manufactures and custom fabricates extruded plastic tubing. The company provides various plastic tubing solutions, including durable HDPE tubing, and maintains ISO Certification with state-of-the-art manufacturing equipment.
Based in City of Industry, CA, J & L Custom Plastic Extrusions, Inc. manufactures custom thermoplastic profiles, rods, and tubes since 1976. They work with over 30 plastic materials, offering prototype to high-volume production. Capabilities include in-house tool and die and fabrication for complex shapes, serving automotive, medical, and aerospace sectors.
Based in Los Angeles, CA, JM Eagle, Inc. manufactures plastic pipe products, specializing in PVC and PE pipe. The company uses advanced technology to create diverse and sophisticated offerings. JM Eagle provides a 50-year warranty on its products, guaranteeing long-term performance and reliability for various applications.
Based in Wheeling, IL, Lakeland Plastics manufactures custom plastic profile extrusions for designers and engineers, producing profiles up to 24” wide. The company also offers crosshead extrusion coating services, applying PVC, Polyethylene, Nylons, or other thermoplastics to various materials.
Based in Murrieta, CA, Medical Extrusion Technologies Inc. specializes in custom tubing extrusions, including single-lumen, multi-lumen, bump, and profile extrusions. They work with a diverse range of thermoplastic materials and FEP heat shrink, offering in-house tooling, product development, and contract manufacturing programs.
Middlefield Plastics, Inc., founded in 1970 and based in Middlefield, OH, specializes in custom plastic extrusions. The company provides tailored solutions for a diverse range of industries, including aerospace and toy manufacturing. They leverage extensive experience to deliver high-quality extruded plastic products for various applications.
Based in Sheboygan, Wisconsin, Northland Plastics, Inc. provides plastic profile extrusion manufacturing services. They supply quality thermoplastic extrusions, complemented by engineering design and fabrication capabilities. The company is ISO 9001:2015 certified, ensuring high standards for custom plastic solutions with fast delivery.
Omega Plastics, LLC provides custom plastic extrusion products from its facilities in Knoxville, TN, and Carrollton, TX. The company specializes in designing and producing tubing, sheets, and complex profiles for industries such as construction, automotive, and medical. They maintain an in-house die and tooling shop.
Based in Atlanta, GA, Pexco specializes in custom plastic extrusion, injection molding, and fabrication services. The company designs and manufactures a wide range of thermoplastic and engineered polymer products. With multiple manufacturing facilities across the United States, Pexco provides solutions for diverse industrial, medical, and consumer applications.
Plastech Corp, based in Addison, TX, specializes in custom plastic extrusion services. They utilize their expertise and in-house tooling to manufacture custom extrusions, from flexible tubing to complex rigid PVC profiles. The company employs various extrusion equipment, including single and twin screw systems, ensuring quality product delivery.
Based in Middlefield, OH, Plastic Extrusion Technologies is a manufacturer specializing in custom plastic profiles and tubing extrusion. With over 100 years of experience and a 45,000 sq. ft. facility, they produce high-quality plastic parts from various resins, serving clients across the United States.
Based in Paramount, CA, Z-Tronix, Inc. manufactures and supplies plastic tubing products and solutions. The company focuses on producing high-quality plastic tubing for various applications. It provides comprehensive solutions for industries requiring specialized plastic tubing, leveraging its manufacturing capabilities to meet diverse client needs.
Based in Plainwell, MI, Preferred Plastics, Inc. provides custom plastic extrusion services. They manufacture plastic products, parts, and components for industrial and consumer applications using innovative extruding processes. The company ensures high-quality parts, superior customer service, and on-time delivery for clients.
Based in San Clemente, CA, Spectrum Plastics Group is a direct provider of plastic extrusion services. They specialize in tubing extrusion, manufacturing single lumen and multi-lumen tubing, co-extrusions, and paratubing. This facility offers full-service capabilities for advanced plastic manufacturing.
Based in Anaheim, CA, USA Extruded Plastics manufactures custom plastic extrusions and tubing. The company works with both virgin and recycled plastic materials, developing custom projects from concept to completion. They serve major private and government companies across America with over 20 years of experience.
Based in Plymouth, WI, WI Plastic specializes in custom plastic extrusions for simple to complex profiles with tight tolerances. The company offers in-house tooling design, manufacturing, and a lifetime guarantee. Capabilities include co-extrusion technology, post-extrusion fabrication, and specialized surface finishes like Spattercoat and hot stamping.
Finger Lakes Extrusion specializes in the manufacturing of flexible plastic tubing solutions. They provide custom extruded products designed for various applications, delivering high performance across multiple industries. The company focuses on producing tubing to meet specific client requirements for diverse industrial needs.
IQ Enterprises provides specialized PPS extrusion services, delivering custom plastic extrusion solutions. The company operates as an ISO 9001:2015 certified provider, focusing on manufacturing capabilities for various industrial applications.
Based in Worcester, MA, Slideways, Inc. was established in 1994. The company manufactures engineered plastic extrusions, specializing in custom profiles for various industrial applications. They also produce a range of wear components, providing durable solutions for demanding environments. Slideways, Inc. focuses on delivering precision-engineered plastic parts.
Found what you're looking for? Unlock 53 emails and 77 phones.
How to Choose a Company
- Verify their expertise in your specific profile geometry complexity (e.g., thin walls, intricate channels) and the particular thermoplastic resins you require, such as rigid PVC, TPE, or engineering-grade polymers like Ultem or PEEK.
- Assess their in-house downstream tooling capabilities, including precision cutting, drilling, punching, or notching, to streamline your supply chain and ensure integrated post-extrusion processes.
- For applications in regulated industries (e.g., medical devices, food packaging, automotive), explicitly require compliance with certifications like FDA regulations (21 CFR), IATF 16949, or AS9100, and inquire about their specific cleanroom capabilities or GMP adherence.
- Inquire about their process control methodologies and metrology equipment, specifically how they manage die swell, maintain critical tolerances, and ensure consistent durometer readings across long production runs.
- Be wary of suppliers offering extremely low tooling costs without a detailed breakdown or clear ownership terms; this often indicates inferior tooling materials, offshore sourcing with extended lead times, or inadequate trial runs leading to costly revisions down the line.
- Evaluate their experience and capabilities in co-extrusion if your profile demands multiple materials, distinct color zones, or varying hardness levels in a single, inseparable profile.
Frequently Asked Questions
How does die swell impact my final plastic extrusion dimensions and how can it be controlled?
Die swell is the phenomenon where the polymer melt expands after exiting the extrusion die, resulting in a profile cross-section larger than the die opening itself. This expansion is influenced by material rheology, melt temperature, and extrusion speed. To control it, experienced extruders meticulously design the die, optimize process parameters, and utilize precise downstream cooling and calibration tooling to draw down the profile to the desired final dimensions, often requiring iterative adjustments during tooling prove-out.
When should I opt for co-extrusion instead of separate profiles or post-extrusion assembly?
Co-extrusion is ideal when your profile requires multiple materials with different properties (e.g., rigid base with a flexible seal, different colors for aesthetics, or integrated conductive stripes) that need to be permanently bonded in a single profile. It often reduces assembly costs, improves aesthetics, and enhances functional integration. However, it requires more complex tooling and process control than single-material extrusion, making it less suitable for very low volumes or when materials are incompatible for bonding.
What are the key considerations when specifying tolerances for custom plastic extruded profiles?
When specifying tolerances, consider the material's inherent stability, wall thickness (thinner walls are harder to hold), the overall profile geometry's complexity, and the capabilities of the downstream tooling. It’s critical to prioritize critical dimensions and communicate the application's true functional requirements. Very tight tolerances, especially on non-critical features, can significantly increase tooling costs, lead times, and piece prices due to more complex die design and rigorous process control.
What drawing formats and information do plastic extrusion companies typically require for an accurate quote?
For an accurate quote, suppliers typically require 3D CAD models (STEP, IGES, SolidWorks files are common) along with 2D drawings that include complete GD&T (Geometric Dimensioning and Tolerancing). Crucially, you must specify the exact material (resin grade, manufacturer, and color), estimated annual volume, any secondary operations needed, and the end application to help the extruder understand critical performance parameters.
What are common hidden costs or pitfalls when sourcing custom plastic extrusion tooling?
Hidden costs in custom extrusion tooling often include unexpected tooling revisions due to under-specification or inadequate initial trials, long-term tooling maintenance and repair (especially for abrasive materials or high volumes), and the need for specialized downstream tooling beyond just the die. A common pitfall is underestimating the prove-out time required to achieve consistent dimensions and surface finish, which directly impacts project timelines and can accrue significant hourly charges if not accounted for upfront.