proc_extrusion

Extrusion

formative · aluminum extrusion, polymer extrusion, profile extrusion

Material is pushed through a die — like toothpaste through a tube — and emerges as a continuous profile of whatever cross-section the die holds. The reason aluminum window frames, plastic gutters, pasta, and the entire 80/20 framing system exist.

Continuous forming process where a billet (metal) or melt (polymer) is forced through a die opening. Aluminum extrusion runs at ~450–500 °C; thermoplastic extrusion at 150–280 °C depending on polymer. Cross-section is constant along the length; complexity limited by die-design rules (uniform wall, no thin tongues).

Scale & Tolerance

  • scale (mm)1 – 30000
  • tolerance (mm)0.3
  • skilladvanced for die design; beginner for specifying off-the-shelf profiles
  • costvery low per meter at volume; die cost moderate to high

Equipment

  • school_shoprare — desktop polymer extruders (Filabot) for filament making
  • professionalpolymer single- and twin-screw extruders; aluminum extrusion presses 1500–10000 tons
  • industrialhorizontal aluminum extrusion lines with quench, stretch, age

Environmental

  • energy_usemoderate to high (especially metal billet preheat)
  • waste_streamoff-cuts, butt-ends — recyclable in-process for both metal and thermoplastic
  • consumablesdie wear, lubricant

Citations

  • book · Lefteri, *Making It: Manufacturing Techniques for Product Design*, 2nd ed. (Laurence King, 2012), 'Extrusion' p. 96.