Metal Extrusion Services
The range of aluminum extrusion applications at Coltwell is an endless amount. From our smallest press size at 110 tons, to our largest at 6500 tons, we consider no shape too large or too small for the extrusion process.
Why Choose Elimold for Metal Extrusion?
Elimold is proud to offer a range of metal extrusion services, serving the needs of various industries and applications. Many of our extrusions are nested, mated, or sliding-fit sets that require careful attention to tolerances and finish quality; our expert team has years of experience handling complex jobs and can easily meet even the most unusual extrusion needs.
We can handle all types of project requirements — including thin wall, complex shape, heat sink, small cross-section, co-extrusion, ram extrusion, reverse extrusion, tri-extrusion, and ultra-precision solutions — and complement these offerings with secondary operations such as punching.
Elimold has both domestic and offshore factories that can fulfill short-, medium-, and large-run projects, and we serve nearly two dozen different industries, including agriculture, automotive, firearms, hydraulics, medical, plumbing, robotics, and telecommunications.
Types of Extrusion and Extrusion Profiles
Elimold partners with the leading extrusion suppliers who utilize the most sophisticated technology to deliver high-quality extrusions. Thanks to our manufacturing network, we can support multiple types of metal extrusion and an endless array of extrusion profiles.
Types of Extrusion
Direct extrusion, also referred to as forward extrusion, is the most common metal extrusion method. With this type of extrusion, a billet of material is pushed through a container by a high-pressure ram. The material flows in the direction of the ram motion and exits through the opening of the stationary die. Direct extrusion allows for larger profile designs and a higher quality surface finish than the indirect extrusion method.
There are some disadvantages to consider with this method. A large amount of friction generates between the material and the walls of the container, which results in decreased die face pressure and temperature variances. These factors make it more challenging to control dimensional consistency and the material’s properties.
With indirect extrusion, the material is placed into a container and secured. The extrusion die moves with a hollow ram over the material, forcing it through the die opening. Indirect extrusion is also sometimes referred to as backward extrusion because the material flows in the opposite direction of the ram motion. Since there is no relative movement between the material and container, there is much less friction with this method, resulting in lower energy use and less heat generation. With less heat, indirect extrusion generally has greater control over dimensional consistency, material properties, and grain size when compared with direct extrusion.
However, the drawback to this type of extrusion is a more significant limitation on overall die profile size, as it must fit inside the hollow ram. The billet’s surface impurities can find their way into the extruded product reducing the overall surface finish and aesthetics.
These are sub-categories of extrusion integrated into the primary methods discussed above. The temperature of the billet relative to the room and material recrystallization temperature defines hot, warm, or cold extrusion. Hot extrusion is when the billet is heated well above the material’s recrystallization temperature, often associated with the direct extrusion method. The heating of the material softens it and prevents work hardening, so it more easily flows through the die, reducing wear on the tooling. Warm extrusion is when the material is heated above room temperature but remains well below the recrystallization point. The material is not heated in cold extrusion and remains at room temperature.
Warm and cold extrusion can increase the hardness and strength of the extruded product due to no excessive raw material heating. These processes work best with high ductility materials, such as aluminum. The warm and cold processes are typical of the indirect metal extrusion method. While not drastically heating the material can provide benefits, it can be harder on the tooling and reduce the lifetime of the die. With this in mind, most manufacturers opt for hot extrusion methods.
Extruded aluminum makes up roughly 80% of all extruded metal products due to its versatility across industries, mechanical properties, diverse finishing options, and high ductility, making it ideal for extrusion processes. Most extruded aluminum alloys are lightweight, resistant to corrosion, and have high thermal and electrical conductivity. Some aspects of each alloy set it apart from the others. To help you choose the right one for your project, we have compiled a table below of the most commonly used alloys we offer and their unique characteristics.
Extruded Aluminum Alloys Comparison Table
|Alloy Name||Description||Characteristics||Suitable Applications|
6061 is a versatile alloy that can be heat-treated to tempers such as 6061-T6. Magnesium and silicone are primary alloying elements that give the material high structural strength, toughness, and weldability.
Transportation components for automotive and marine environments
6063-T5 is a very economical heat treatable alloy with a smaller grain structure than 6061 alloys. 6063 is more common for extrusions than 6061. It can form parts with thin walls and responds well to finishing processes, making it suitable for decorative applications.
Decorative trim, heat sinks, architectural components
* Typical minimum representative values ; material temper may affect mechanical properties
Extrusion profiles represent the cross-sectional shape that forms the extruded product. elimold custom manufacturing services enable you to get extruded parts made with custom extrusion profiles.
If you are looking to save money and time by post-processing your existing aluminium extrusions, we can do that too! Listed above are some ready-made aluminium extrusions that we can modify through other manufacturing processes, such as our CNC machining services.
Get Your Metal Extrusion Project Started Today
Our engineers are ready to work with you to make sure you get great parts fast. When you submit your 3D design files, we will consult with you to ensure design for manufacturability in order to get parts that meet and exceed your expectations. Contact us for your free quote and design review today.Get Free Quote
Metal Extrusion Advantages
Modern extrusion presses and processes produce close tolerance extruded shapes that are durable and dimensionally stable. The process is also suitable for brittle and ductile materials.
Available Extruded Part Finishes
Elimold makes adding additional finishing steps to your metal extrusion project easy. Our vast network of finishing suppliers allows us to apply a variety of finishes to your parts. We have what you need, whether it’s functional or cosmetic finishes. The finishes we offer for our metal extrusion process are detailed below.
The finish will be left unprocessed and remain as-extruded. Surface roughness can vary between alloys due to differences in grain structure but typically will fall between 64µin – 125µin Ra. Noticeable grain lines or discolored streaks may be present.
Type II anodizing creates a corrosion-resistant oxide finish. Parts can be anodized in different colors—clear, black, red, and gold are the most common. Type III is a thicker finish and creates a wear-resistant layer in addition to the corrosion resistance seen with Type II. Anodized coatings are not electrically conductive.
This is a process where powdered paint is electrostatically sprayed onto a part, then baked in an oven. This creates a strong, wear- and corrosion-resistant layer that is more durable than standard wet painting methods. Various colors and textures are available to create the desired aesthetic.
All extruded metal parts can be wet painted in various paint formulations and colors. For color matching, paint brand and number should be specified on your included drawings or notes.
Extruded parts can be plated with electroless nickel, nickel, brass, tin, chrome, chromate, Teflon, silver, and gold.
A chromate conversion coat can be applied to protect aluminum from corrosion and improve the adhesion of paints and primers. Chemical film conversion coatings also allow the metal to retain its electrical conductivity while providing corrosion protection to the surface.
Parts are subjected to vibratory media tumbling to remove sharp edges and smooth surfaces. Suitable for smaller pieces that can fit within the bowl or barrel of the tumbler.
Don’t see the finish you need? Select “custom” in our quoting interface and let us know what you are looking for, and we will be happy to explore additional options for you!
elimold Metal Extrusion Services
If you are looking for an extrusion profile cut in a certain length and the volume you require is high, you should definitely go with an extrusion company directly. There are lots of extrusion companies dealing with high-volume production. Though, these companies are not willing to handle low-volume aluminum & plastic extrusion projects, unless you are one of their VIP customers. so it is very difficult get prototype aluminum extrusions & prototype plastic extrusions. At elimold, we have solid partners for short run custom aluminum extrusions & short run plastic extrusion services. They take good care of our projects, both in quality and lead times. We also routinely do quality control on your project before shipment.
Compared with traditional extrusion companies, we have a large amount of CNC machines, so we can do precision post-machining in house.
On-Time Delivery with Tested Performance
Working to complete projects on-time and on-budget, we have 2- to 48-hour response times on RFQ’s 95% of the time, as well as a 90%+ OTD (on-time delivery) against our commitments. We also have robust quality control and quality assurance processes, which help ensure that our finished products work the way they’re supposed to.