Extrusion is an additive manufacturing process that involves heating a material and pulling it through a die to create a continuous length with the desired cross-section. The technique is similar to pushing Play-Doh through a mold.
The formed length can then be sawed into sections. Additional machining operations may be necessary to add holes or edges, but extrusion is an easy way to form the primary shape efficiently. In fact, it’s often a cost-effective alternative to complex CNC machining.
Our engineers have identified the best way to leverage extrusion, essential considerations for the process, and why it pays to work with an experienced precision machine shop like Reata.
When to Use Extrusion to Replace Complex CNC Machining
The best candidates for extrusion are parts with a uniform cross-section or complex features consistent along the part’s length. These criteria include shapes that are difficult to machine but don’t require high precision to function correctly.
Common examples of extruded parts include heatsink fins. The rows of identical parts with a uniform cross-section are ideal for extrusion. Machining these parts would be time-consuming, requiring multiple passes and material removal using a mill.
Extruding the fins creates nearly complete shapes requiring minimal complex CNC machining.
Extrusion for custom shapes
If you’re wondering whether extrusion can be used for complex, custom shapes, the answer is yes as long as there is a consistent feature along the length of the part.
Extrusion can be tailored for custom shapes—even hollow ones—to reduce the amount of material and machining needed. All we need to do is create a custom die.
How Extrusion Saves Time and Material Costs in Contract Manufacturing
In the eyes of our experienced engineers, replacing complex CNC machining with extrusion when appropriate is a no-brainer.
Extrusion streamlines manufacturing by producing parts that are close to the final shape. This process has fewer steps than CNC machining, which reduces labor costs, time spent, and the risk of human error as parts are moved from machine to machine.
Extrusion also requires only one piece of material to push through the die as opposed to several pieces being cut to size when CNC machining. The extrusion process reduces the material used, creating additional cost savings.
Work with a Precision Machine Shop Experienced in Extrusion
The extrusion process is relatively simple, but that doesn’t mean just any machine shop can achieve a high level of quality.
Experienced precision machine shops like Reata have the Design for Manufacturability experience to identify when parts are suitable for extrusion and design effective, complex dies. At Reata, we also cultivate excellent relationships with extruding vendors to provide the best service to our customers.
Keep in mind that the extrusion itself is typically only one step in the manufacturing process. For maximum cost savings and efficiency, work with Reata. We can manage your part’s production from start to finish and ensure you get the optimal cost, quality, and lead time.
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