Extrusion dies are templates through which raw materials are pushed in order to form objects that replicate the same shape over a length of material. These objects have a fixed cross-section; the simplest and most common extruded items are copper pipes. Extrusion dies come in many designs, not all of which are circular like pipe extruders. Extrusion dies can be used to make a remarkable array of cross-sections in various shapes, such as x-shaped beams. Extrusion die companies sell dies capable of extruding different types of materials including metals, plastics, ceramics and even foods. Spaghetti is an example of extruded food, created from raw pasta being pushed through an extrusion die.

Creating piping, or extruding materials, from aluminum beams in high-rise buildings to simpler rubber extrusion dies found in food-processing plants, is a high-paying industry. Like any field that has a high demand with a low pool of qualified prospects, there is tremendous opportunity to find a high paying job in the extrusion dies industry. Consider the following suggestions to get the best training:

1. Learn the techniques for using extruder dies equipment.

2. Keep an eye on what other extrusion dies suppliers are looking for in employees.

3. Offer continuing education programs, such as seminars and workshops.

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Find training in the extrusion die industry

When it comes to the extrusion dies industry, there are not a lot of resources that make finding extrusion dies education and training easy. Training must include education in plastic extrusion dies and aluminum extrusion dies at a minimum, since these are the most common types. There are several online resources that you can use to help get yourself quality training in this competitive field.

I recommend: Paulson Training Programs offers several courses pertaining to the extrusion die industry, including training on both single and twin extrusion. These courses are also tools for extrusion dies manufacturers to keep their employees trained and up to date on relevant certifications. Another way to receive training in extrusion is to complete an apprenticeship. You might also consider HyperXtrude Training from Altair Engineering.

Gain qualifications each extrusion die supplier is looking for

Extrusion die companies pay competitive wages and offer great benefits, but you need the right training to get your foot in the door. Look for training that reputable extrusion die companies want from their employees.

I recommend: Visit O Net Online to learn more about how an apprenticeship in the extrusion industry can help you and how you can find one. The Plastics Institute of America, the official industry association of the plastics industry, offers extrusion training that includes die design principles.

Stay up to date on techniques for working with extruder die equipment

Extrusion die manufacturers and suppliers are looking for the best employees they can find. This includes employees willing to continue their education about the equipment. Seminars and workshops are a good way to stay abreast of all the latest techniques and technological advances in the industry.

I recommend: University of Massachusetts Lowell offers seminars and on site training for extrusion die techniques. Penn State Eerie has both on site and off site seminars to keep you up to date on all the newest extrusion die technology and techniques.

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• •  Another application of extrusion is in the pharmaceutical industry. Miniature extrusion dies are used in the manufacturing of various forms of chemotherapy.

Extrusion dies are used to precisely manufacture products. It is important to find extrusion die manufacturers and extrusion die suppliers that can adhere to your design specifications. Deviations in extrusion die design manufacture can result in product safety issues.

Consider how you want your extrusion die to look after it is produced. Will it be packaged directly for the consumer market? How many iterations of prototype will you get for your quoted price? Other questions to ask your potential extrusion die maker are:

1. Can you specify packaging processes or materials for your custom extrusion and will you also custom design a box?

2. What is the lead time on custom extruder dies? You'll need to know the time frame and manufacturers who have less lead time may be more attractive to you.

3. Are your extrusion dies tooled in-house? In-House tooling is important because the manufacturer is not outsourcing the work to someone else and will have control over the quality.

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Educate yourself on aluminum extrusion dies and tolerances

Tolerance is deviation from design dimensions. Billet temperature, extrusion speed, die shape and type, amount of post-stretch, and air temperature are factors that can affect aluminum extrusion die tolerance. These tolerances can impact the design of the product.

I recommend: Consult The Aluminum Association for industry standards. The association is also a terrific avenue for finding aluminum extrusion die manufacturers and suppliers. Southern Carbide Die, Inc. and Alexandria Extrusion Company (AEC) are two companies who specialize in aluminum extrusion dies.

Ask to see piece parts from your extrusion die maker

You will want to monitor your extrusion die manufacturers' work and the best way to do this is to ask for a piece part review. This will allow you to spot a manufacturing flaw immediately. Precision in extruder die manufacturing is imperative.

I recommend: Midland Plastics and Excalibur Extrusions are great sources for plastic extrusion dies and custom fabrication services. Thrust Industries specializes in plastic extrusion dies for the telecommunications, electronics, automotive, and computer industries.

Consider extrusion die design software

A die design software package can save you money. Advanced software capabilities can reduce setup time and shorten tooling time. Most design software programs were built to integrate with Computer Automated Design (CAD) systems, which has been the industry standard for years.

I recommend: Cimatron and Striker Systems offer 3-D die design software and their solutions have a feature that allows the user to switch to a 2-D interface design if that is needed.

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• •  Always select extrusion die companies that are ISO 9001:2000 certified to ensure your products meet manufacturing standards.
• •  Take advantage of extrusion die design expertise from your manufacturer before committing to a specific material. If you haven't completed your design, meet with your manufacturer because he may be able to suggest alternate materials that will cut down on production time.

An extrusion die is an important component of an extrusion machine that decides the quality of the extruded products. Before selecting an extrusion die, you must identify your application requirements, such as the material to be extruded or the required production rate.

While interacting with the suppliers of industrial extrusion dies, you will need to understand various technical terms that indicate type, specifications and technologies for different extrusion dies.

This guide will explain some extrusion dies key terms, such as solid die, hollow die, extrusion speed and hot or cold working.

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Hollow die

As the name indicates, these dies are useful for producing hollow or semi-hollow shapes. However, extruded profiles have one or more seams.

I recommend: You can read through the glossary of technical terms at Extruded Profile, a business-to-business (B2B) marketplace for extrusion products.

Solid die

These dies are useful for extruding open profiles, such as angles, bars and channels. These dies have a metal plate with an aperture with a cross-section that is similar to the required profile.

I recommend: AACOA, a supplier of extrusion products, offers a glossary of technical terms that explains hollow and solid dies.

Billet

A billet is the raw, solid material kept in the extrusion die for further processing. Billet dimensions are extremely important for the selection of extrusion dies. Generally, 'billet' is the term used for raw material in a metal extrusion process.

I recommend: Automation Supplies provides an informatory website that offers an aluminum extrusion glossary.

Butt

A butt (also called a heel) is the unextruded portion of the billet that remains in the extrusion die even after the extrusion process is complete.

I recommend: Alumax, a provider of bath enclosure and shower doors, offers a glossary of technical terms, including billet and butt.

Extrusion speed

Extrusion speed is an important specification of any extrusion process. Before selecting an extrusion die, you must evaluate the required extrusion speed.

I recommend: Burak Aluminium offers a glossary of technical terms such as hollow dies, solid dies and extrusion speed.

Cold working (or cold forming)

Before buying or renting an extrusion die, you must specify the type of extrusion operation that you want to opt for. Cold working is when the metal working operation is performed at room temperature. However, extrusion at room temperature might induce some stresses in the extruded product.

I recommend: You can browse through a metal forming glossary at Advantage Fabricated Metals, a manufacturer of metal components for original equipment manufacturing (OEM) applications.

Hot working (or hot forming)

As the name indicates, hot working is when the metal working operation is performed at high temperatures. At higher temperatures, the yield strength of a metal or alloy is less than its value at room temperature.

I recommend: Sandmeyer Steel Company, a supplier of industrial steel products, offers a glossary of technical terms, including cold forming and hot forming.

Extrusion dies pricing and costs include the cost of the raw material, the manufacturing process and additional treatments of the product. The primary advantages of this manufacturing process are the ability to create a product with any desired cross section and the ability to use brittle materials.

Extrusion can be used to make products that are indefinitely long and extrusion is commonly performed over a wide range of temperatures. Hot extrusion is used by extrusion die manufacturers on metals, and the required temperature varies according to melting point of the metal being used. The biggest disadvantage of hot extrusion is the additional expense of the machinery and its maintenance. The following are some of the more common types of materials used in extrusion:

1. An extrusion die made of plastic. Plastic extrusion is used to make a variety of plastic products, especially piping.
   
2. An aluminum extrusion die supplier. Aluminum products are used in applications requiring a metal that is light and corrosion-resistant.
3. Rubber extrusion die manufacturers. These products can be made with virtually any desired physical properties.
   

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Examine the prices of products made with plastic extrusion dies

Companies that use a plastic extruder die may offer products in a fixed quantity or a continuing product line. They can produce piping in a variety of sizes, shapes and colors.

I recommend: Inline Plastics offers custom plastics extrusions and can eliminate many of the costs of secondary operations. Available Plastics specializes in cost effective PVC plastic extrusions.

Look at the cost of aluminum extrusion dies

Companies that perform aluminum extrusion commonly include other treatments to aluminum, such as heat treating and anodizing. The cost of the aluminum itself and the required processes help determine the cost of the final product.

I recommend: SECAT provides information on the aluminum extrusion process and addresses the cost of standard extrusion dies vs. those of custom extrusion dies. Futura Industries discusses the effect of the raw material on the cost of aluminum extrusions.

Obtain prices from companies that make products with rubber extrusion dies

Rubber extrusion dies commonly produce piping from many different types of rubber. The specific type of rubber directly affects the final cost of the product.

I recommend: Warco provides a variety of extruded rubber products and offers an online price list. Seals Unlimited specializes in custom gaskets and seals made with a rubber extrusion process.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  Extruder dies have characteristics that include the movement of the extrusion, which is measured relative to the ram. A process that moves the ram towards the die is called 'direct extrusion' and a process that involves moving the die towards the ram is known as 'indirect extrusion'. The position of the press may be horizontal or vertical and the drive may use hydraulic or mechanical pressure.