Extrusion: the route, the tolerances it holds, materials and design tips, with an indicative cost. One of 56 processes in the free finder.
Bulk formingFamily
+/-0.2mmTypical tol.
5Route steps
79Parts in finder
Extrusion pushes heated metal through a shaped die to produce a long part with a constant cross section, like toothpaste from a tube.
At a glance
When to use it, and when not
Best for
Aluminium and other profiles: frames, heat sinks, rails and trim in long runs.
Watch for
Constant cross section only; tight tolerances and thin webs need care.
Step by step
The typical route
Raw material to finished part. Steps vary with material, volume and tolerance; this is the free route from the finder.
Heat billet
Heat the aluminium/polymer billet.
Tooling Furnace Tolerance - Lead -
Extrude
Push through the profile die to form the section.
Tooling Extrusion die Tolerance - Lead -
Stretch & cut
Stretch-straighten and cut to length.
Tooling - Tolerance - Lead -
Age
Age (T5/T6) for aluminium.
Tooling Furnace Tolerance - Lead -
Finish
Anodise/paint and pack.
Tooling - Tolerance - Lead -
Precision
Tolerances it can hold
TYPICAL TOLERANCE IT CAN HOLD
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials
Materials it suits
Grade
Why it suits this
Aluminium 6063
Great extrudability, finish
Aluminium 6061
Structural
PVC/plastic
Cheap profiles
Design
Design tips
A few general pointers for Extrusion. The full, part-specific DFM list is in the dossier.
Unbalanced wall thickness.Even the section.
Sharp corners.Add radii.
Cost
What it costs
Constant cross-section profiles (alu especially); cheap die, priced largely by weight per metre.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for your part at your volume, in your currency, are in the dossier.
MODEL EST.
$2.6 to 6.2per part at 100 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
GET THE FULL DOSSIER
Everything you need to quote and source it
The free route above is yours. To actually put a number on this process and buy it well:
Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
A quote checker that tells you if a supplier quote is fair, and the red flags to watch
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Extrusion pushes heated metal through a shaped die to produce a long part with a constant cross section, like toothpaste from a tube. The typical route is: Heat billet; Extrude; Stretch & cut; Age; Finish. Aluminium and other profiles: frames, heat sinks, rails and trim in long runs.
What does Extrusion cost per part?
It depends on size, tolerance and volume. As a rough ballpark it starts around $2.6 to 6.2 per part at low volume and falls with quantity. The dossier gives should-cost at your exact volume and currency. Model estimates, not quotes.
What tolerance can Extrusion hold?
Typically about +/-0.2 mm, tighter with extra finishing operations at higher cost.
What materials suit Extrusion?
Common choices are Aluminium 6063 (Great extrudability, finish); Aluminium 6061 (Structural); PVC/plastic (Cheap profiles).
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
