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Extrusion Services

KARV automation offers you on-demand industrial extrusion services to produce high-quality parts of fixed shape and cross-sectional profile. Our in-house workshops are equipped with modern extrusion machines & our skilled engineers can produce parts with higher accuracy.

We have a comprehensive range of various industrial-grade materials to fulfill your every extrusion requirement. KARV automation offers all types of high-grade plastic and metal materials for the manufacturing process. Our extrusion services offer tolerances up to ± 0.02 mm along.

With a faster turnaround time of as minimum as 2-3 days, KARV automation offers a full range of extrusion services for small-batch and mass manufacturing. If you have a custom manufacturing requirement using an extrusion process, our team can accomplish that with shorter lead times. Also, we bring in multiple surface finishing options like anodizing, polishing, etching for post-production prototyping—experience high-accuracy extrusion services worldwide with us.

What is Extrusion?

Extrusion is a manufacturing process widely used in various industries to create objects with a consistent cross-sectional profile. It involves pushing or forcing a material, typically a malleable plastic or metal, through a die to form a continuous shape. The initial step entails introducing the raw material, typically in the form of pellets, into a hopper. Subsequently, the material is conveyed into a heated barrel. Within the barrel, the material is melted and pressurized, and it is then forced through the die, which determines the final shape and size of the extruded product. Cooling mechanisms are employed to solidify the material as it emerges from the die. Extrusion offers several advantages, such as high production rates, versatility in creating complex shapes, and cost-effectiveness. It is commonly used to manufacture products like pipes, tubes, rods, and various profiles used in the construction, automotive, and packaging industries.

Plastic Extrusion

Plastic extrusion is a manufacturing process that produces continuous lengths of plastic profiles with a consistent cross-sectional shape. It is a widely employed technique in the plastics industry for creating various products, including pipes, tubes, rods, sheets, and profiles with complex geometries.

The plastic extrusion process involves melting raw plastic material and forcing it through a die, a specially designed tool with a specific shape and size. The plastic material is typically in pellets, granules, or powder. The extruder, a machine specifically designed for this purpose, comprises a heated barrel with a rotating screw inside. The screw continuously moves the plastic material forward while melting it due to the heat generated by the barrel.

As the plastic material progresses through the extruder, it undergoes a combination of melting, mixing, and pressurization. The screw compresses the molten plastic and forces it through the die, where it takes on the desired shape. The die determines the extruded plastic product's final dimensions and cross-sectional profile. The die can be customized to produce shapes, such as circular, rectangular, or specialized profiles with intricate designs.

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Once the plastic material passes through the die, it is rapidly cooled using various methods, such as water baths, cooling rollers, or air cooling. Cooling is essential to solidify the molten plastic and maintain the desired shape and dimensions. Following the cooling phase, the extruded plastic product is precisely trimmed to the desired length utilizing either a saw or a specialized cutter. Plastic extrusion offers several advantages over other manufacturing processes. It allows for high-volume production with consistent product quality and excellent dimensional accuracy. The process is also versatile, as it can be used with various thermoplastic materials, including polyethylene, polypropylene, PVC, polystyrene, and many others. Additionally, extrusion enables the creation of complex profiles and shapes that may be difficult or costly to produce using alternative methods.

The applications of plastic extrusion are extensive. Extruded plastic products are used in various industries, including construction, automotive, packaging, electronics, and consumer goods. Examples of extruded plastic products include PVC pipes for plumbing and electrical conduit, window frames, weatherstripping, plastic sheets for packaging and signage, plastic profiles for automotive trims, and plastic rods for 3D printing.

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Metal Extrusion

Metal extrusion is a manufacturing process that involves shaping or forming a metal workpiece by forcing it through a die, or a series of dies under high pressure. It is a widely used technique for creating complex cross-sectional profiles and long continuous lengths of metal with consistent shapes and dimensions. Metal extrusion offers several advantages, such as cost-effectiveness, high production rates, and the ability to work with various metals.
The process of metal extrusion typically involves the following steps:

  • Billet Preparation: A billet, which is a cylindrical or rectangular block of metal, is selected based on the desired end product. The billet is usually heated to improve its plasticity and make it easier to deform during extrusion.

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  • Die Design: A die is a specially designed tool with an opening that matches the desired shape of the extruded metal. The die may consist of multiple sections, determining the extruded profile's final dimensions and surface finish.
  • Extrusion Process: The heated billet is placed in a chamber within the extrusion press. A ram exerts high pressure on the billet, forcing it through the die opening. The metal is effectively squeezed or pushed through the die, taking on its shape as it emerges on the other side.
  • Cooling and Cutting: As the extruded metal emerges from the die, it may undergo cooling using water or air to help it retain its shape. After cooling, the extrusion is cut to the desired length using saws or other cutting tools.

Metal extrusion can be performed using different methods, including direct extrusion and indirect extrusion:

  • Direct Extrusion: In this method, the billet is placed in a chamber, and the ram pushes it directly through the die. The extruded metal moves in the same direction as the ram and the process is typically performed in a single stroke.
  • Indirect Extrusion: In indirect extrusion, the die is placed at the end of the hollow ram, and the ram moves toward the billet. During the extrusion process, the metal moves in the opposite direction of the ram, while the ram itself remains stationary or experiences minimal backward movement.

Metal extrusion finds applications in various industries, including automotive, aerospace, construction, and manufacturing. It produces many products such as tubes, rods, bars, profiles, and even complex shapes like heat sinks and window frames. The ability to create continuous lengths of metal with a consistent cross-section makes extrusion an efficient and cost-effective method for mass production.
The choice of metal for extrusion depends on the desired properties of the final product. Commonly extruded metals include aluminum, copper, brass, steel, and various alloys. The process can also be used with non-metallic materials like plastics, ceramics, and composites.

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Types of Extrusion Processes

KARV automation offers a complete range of extrusion processes to help you with all custom requirements. Here are some of the commonly-used extrusion processes:

Cold Extrusion

In cold plastic or metal extrusion, the material blocks are pushed through a die at or below room temperature. In this manufacturing process, the material blocks in the form of a slug and then poured into the cast’s feeder. High pressure at the feeder combines the material parts to form the final product.

Hot Extrusion

In a hot plastic or aluminium extrusion process, the metal goes through heating at a higher temperature, and it’s force-pushed into the die. The high temperature can go from around 340°C to 700°C. This extrusion process happens above the recrystallization temperature.

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Friction Extrusion

In this process, the machine generates higher friction when the metal slug and the design die rotate at high-speed to create friction. The generated heat helps the metal to pass quickly through the design die of the custom shape.

Micro Extrusion

This modern process creates micro-sized objects with highly-intricate geometries. In the micro extrusion process, the cast’s cross-section area is 1 mm, and it helps develop micro-objects at a higher speed. The micro extrusion process is ideal for manufacturing small-sized mechanical spare parts.

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Applications of Extrusion

Extrusion is a widely-used manufacturing technique, and multiple industries leverage its strong potential to boost their operations. Some of the industrial applications of extrusion are:

  • The extrusion process widely leverages in manufacturing and hollow pipes and tubes
  • It is an ideal process for manufacturing windows, doors, frames
  • Extrusion is suitable for performing complex structural work
  • Extrusion is used to produce various electric systems
  • It is used to create high-quality structures for machine guarding

Surface Finishing Options

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KARV Automation’s team offers a wide range of surface finishing to cater to your required texture. Some of the common surface finishing includes:

  • Polishing
  • Chrome Plating
  • Painting
  • Sanding
  • Etching
  • Anodizing

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Advantages of Extrusion

Extrusion offers numerous advantages, including versatility, cost-effectiveness, complex shape capabilities, high production rates, enhanced mechanical properties, tailored material characteristics, seamless integration, surface finish options, and recycling opportunities. These advantages make extrusion a preferred choice for various industries, including automotive, construction, aerospace, consumer goods, etc.

  • Versatility: Extrusion exemplifies a remarkably versatile manufacturing process capable of generating an extensive array of products featuring intricate cross-sectional profiles. It allows for creating of various shapes, including solid bars, tubes, profiles, and hollow sections.
  • Cost-effective: Extrusion offers significant cost advantages compared to other manufacturing processes. This process operates continuously, enabling the production of substantial quantities of products within a limited timeframe. The tooling costs are relatively low, and the process is highly efficient, minimizing material waste.

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  • Material utilization: Extrusion enables efficient material utilization by using a continuous process. The material is forced through a die, resulting in minimal waste. Moreover, the ability to extrude various materials, such as metals, plastics, and composites, allows for selecting the most suitable material for the application.
  • Complex shapes and designs: Through extrusion, intricate shapes and designs can be fabricated, surpassing the capabilities of alternative manufacturing processes, which often struggle or fail to achieve such complexity. The process allows for precise control over the shape and dimensions of the final product, including intricate patterns, thin walls, and varying thicknesses.
  • High production rate: Extrusion is a high-speed manufacturing process, making it suitable for large-scale production. The continuous nature of the process ensures a consistent output, resulting in faster production rates compared to other methods. This is particularly advantageous for industries that require high volumes of products.
  • Enhanced mechanical properties: Extrusion can improve the mechanical properties of materials. During extrusion, the material undergoes plastic deformation, which can refine the grain structure and enhance strength and durability. This makes the extruded products ideal for applications requiring high strength and wear and tear resistance.
  • Tailored properties: Extrusion allows for the customization of material properties to meet specific requirements. By selecting different alloys or adjusting the extrusion process parameters, it is possible to achieve desired characteristics such as hardness, flexibility, conductivity, or heat resistance.
  • Seamless integration: Extrusion enables the creation of long, seamless components without additional assembly processes. This reduces the number of joints or seams in the final product, enhancing its structural integrity and reducing the risk of failure.
  • Surface finish options: Extruded products can have a variety of surface finishes, ranging from smooth to textured. It is possible to improve the appearance, corrosion resistance, and functionality of the extruded parts by incorporating various surface treatments, such as polishing, anodizing, or coating.
  • Recycling opportunities: Extrusion facilitates the recycling of materials. Excess material, trimmings, or rejected parts can be collected and reused during extrusion. This promotes sustainability and reduces waste, making extrusion an environmentally friendly manufacturing method.

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Reasons to Partner with KARV Automation

KARV Automation offers a complete range of on-demand industrial extrusion services. From high-grade metal to plastic extrusion services, our services got you covered. We offer both on-shore and off-shore extrusion worldwide with the shortest turnaround time. Get in touch with KARV automation to know more about our services.

Superior Expertise: KARV Automation is a recognized leader in extrusion automation, our team consists of exceptionally skilled professionals who possess extensive industry knowledge and experience.

Cutting-Edge Technology: We utilize state-of-the-art automation technologies to optimize the extrusion process, ensuring maximum efficiency, precision, and quality in every project.

Customized Solutions: We understand that every extrusion operation is unique, our team excels in crafting tailor-made solutions that are meticulously designed to cater to the distinctive needs of our clients. Collaborating closely with you, our team of experts dedicates their expertise to creating bespoke automation systems that seamlessly integrate with your current infrastructure.

Increased Productivity: By implementing our automation solutions, you can significantly enhance your productivity levels. Our streamlined processes minimize downtime, reduce waste, and boost overall production capacity, allowing you to meet increased demands efficiently.

Outsource: Outsource your manufacturing requirements to KARV Automation for top-notch product quality at a reduced cost. We have our full-fledged setups globally, and we can also manufacture from India and China. When you are with KARV, you don't have to worry about project delivery and quality. KARV holds the entire responsibility of your project till the delivery.

Cost-Effective Solutions: Our automation systems are designed to deliver cost savings in the long run. By optimizing the extrusion process, we help minimize material waste, energy consumption, and labor requirements, resulting in improved profitability for your business.

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Quality Control and Consistency: We prioritize quality control at every stage of the extrusion process. Our automation solutions ensure consistent output, reduced defects, and improved product quality, enhancing customer satisfaction and loyalty.

Reliability and Support: KARV Automation is known for its reliability and commitment to customer satisfaction. We provide comprehensive support throughout the implementation process, including installation, training, and ongoing technical assistance to ensure smooth operations.

Competitive Advantage: By partnering with KARV Automation, you gain an industry edge. Our advanced automation solutions enable you to stay ahead of the competition by delivering superior products, shorter lead times, and increased operational efficiency.

Innovation-Driven Approach: We continuously invest in research and development to stay at the forefront of extrusion automation technology. Our commitment to innovation ensures that you benefit from the latest advancements, unlocking new possibilities and opportunities for your business.

Industry Reputation: With a solid track record and a portfolio of successful projects, KARV Automation has established a formidable reputation for its unwavering commitment to excellence within the extrusion industry. When you hire us, you can trust that you work with a trusted and respected partner.

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