Extrusion Process

Extrusion Process
Extrusion is a process that forces metal or plastic to flow through a
shaped opening die. The material is plastically deformed under the
compression in the die cavity. The process can be carried out hot
or cold depending on the ductility of the material.

The tooling cost and setup is expensive for the extrusion process,
but the actual manufactured part cost is inexpensive when
produced in significant quantities.
Materials that can be extrudes are aluminum, copper, steel,
magnesium, and plastics. Aluminum, copper and plastics are most
suitable for extrusion.

Aluminium is particularly good for

manufacturing complex parts with
multiple features, which can help
reduce costs through easier assembly
and a lower number of parts.

An extruded aluminium sunroof channel

Extruded aluminium roof rails.

Side intrusion beams made from

extruded aluminium

Examples of parts made by extrusion

The cross section of the extrusion can be tailored-made for a

relatively small cost

Examples of parts made by extrusion

Extrusion - Design Consideration

The minimum wall thickness which can
be extruded for aluminum is dependent
of the particular shape, and the smallest
circumscribed circle as well as the alloy.

Circumscribed
circle

Extrusion
shape

Circumscribing Circle Diameter

(CCD): smallest diameter circle
into which the extruded cross
section will fit.

Extrusion - Design Consideration

Extrusion - Design Consideration

Tolerances
Standard industry tolerances usually provide adequate precision
for most applications

Angular tolerances will be 1 to 2 degrees

Flatness tolerance across a profile is .004 per inch of width.

Extrusions will be straight within 0.0125 inch per foot of length.

The approximate twist tolerance will be .5 degrees per foot.

General Design Recommendations

Limit irregular shapes, sharp corners,
and very thin sections.
Avoid thin walls sections
Commonly specified minimum wall
thicknesses include:
Aluminum 1 mm
Carbon steels 3 mm
Stainless Steel 5 mm