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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.
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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 that is used to produce objects of fixed cross-sectional profiles. In this process, the metal or plastic is forced into a closed cavity using a hydraulic or a mechanical press. In this process, the machines produce shear and compressive forces to form the final shape—the die in which the material block is contained, coated with a wear-resistant material.
Popular materials used in the polystyrene extrusion process are high impact polystyrene (HIPS), PVC, polyethylene, polypropylene, and ABS. Widely-used plastic extrusion applications are brush products, refrigeration, HVAC, cable and wire.
In metal extrusion, a cylindrical billet inside the closed cavity is forced against a die of the fixed cross-section. These fixed cross-section profile’s extruded objects are known as extrudes. Commonly-used metal is copper, aluminium, steel, and magnesium. Metal extrusion produces parts with an excellent surface finish. With metal extrusion, engineers can achieve a minimum wall thickness of up to 1mm.
Types of Extrusion Processes
Cold ExtrusionIn 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.
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Hot ExtrusionIn 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.
Friction ExtrusionIn 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 ExtrusionThis 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.
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
Advantages of Extrusion
- Extrusion is ideal for both small-batch and mass manufacturing
- It offers more excellent manufacturing flexibility in both plastic and metal materials
- Extrusion is highly cost-effective as compared to other industrial manufacturing processes
- It’s ideal for mass manufacturing with accurate design repeatability
KARV Automation’s team offers a wide range of surface finishing to cater to your required texture. Some of the common surface finishing includes:
- Chrome Plating