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Extruded Components Aluminum Profiles & Rubber/Silicone Extrusions

We design and produce custom extruded profiles for structural frames, thermal rails, seals, gaskets and decorative trims. Capacities include aluminum extrusion, rubber and silicone extrusion, co‑extrusion and post‑process machining and finishing to deliver production‑ready parts for demanding industries.

  • Custom die design and prototype profile validation
  • Aluminum structural & thermal profiles, elastomer seals and silicone extrusions
  • Secondary operations: cut‑to‑length, CNC machining, drilling, anodize and assembly
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Aluminum Profiles

Lightweight structural and thermal rails with custom cross-sections.

Rubber & Silicone

Seals, gaskets and co‑extruded profiles for environmental protection.

Secondary Operations

CNC machining, drilling, anodize and assembly for finished parts.

What is an Extruded Component?

Extrusion produces continuous profiles with uniform cross‑sections by forcing material through a shaped die. Aluminum extrusion is used for structural rails, heatsink fins and architectural trims. Rubber and silicone extrusion produce flexible seals, gaskets and profiles with complex cross‑sections for environmental protection and mechanical interfaces. We provide design, die development, trial runs and full production — including co‑extrusion where rigid and flexible materials are combined in a single profile.
Extrusion produces continuous profiles with uniform cross‑sections by forcing material through a shaped die. Aluminum extrusion is used for structural rails, heatsink fins and architectural trims. Rubber and silicone extrusion produce flexible seals, gaskets and profiles with complex cross‑sections for environmental protection and mechanical interfaces. We provide design, die development, trial runs and full production — including co‑extrusion where rigid and flexible materials are combined in a single profile.
Aluminum Extrusions — Structural & Thermal Profiles

Aluminum Extrusions — Structural & Thermal Profiles

We extrude 6061 and 6063 alloys into complex profiles used for housings, frames, rails and thermal fins. Profiles can be designed with integrated mounting features, internal channels for coolant, and thermal fin geometries for passive heat dissipation.

Typical aluminum capabilities

  • Profile cross‑section complexity up to 200–300 mm wide (depending on press)
  • Wall thickness control, tight tolerances on critical features
  • Post‑extrusion stretching, straightening and aging for mechanical properties

Secondary machining & finishing Cut‑to‑length, CNC

Cut‑to‑length, CNC milling/drilling/tapping, surface treatments (anodize, powder coat), thermal anodize for improved heat transfer and mechanical fastening integration.

Rubber & Silicone Extrusions — Seals, Gaskets & Flexible Profiles

We extrude EPDM, NBR, FKM (Viton), silicone (VMQ/LSR-compatible compounds) and TPE/TPU for seals, cable gaskets, edge trims and vibration isolators. Co‑extrusion and overmolding are available to combine different durometers or materials in a single profile.

Design considerations

We recommend consistent wall thickness, controlled radii and draft-friendly features to avoid die swell and ensure dimensional stability. Tooling includes mandrels and vacuum sizing for tight tolerances.

Post‑process & vulcanization

Continuous vulcanization ovens, post‑cure options and automated trimming for long, consistent runs; assembly with adhesive or mechanical fasteners as required.
Rubber & Silicone Extrusions — Seals, Gaskets & Flexible Profiles
Die Design & Tooling

Die Design & Tooling

Custom die engineering is central to profile quality. We design dies to control extrusion velocity, reduce weld lines, optimize feed geometry and manage die swell. Prototype dies are validated and iterated before committing to hardened production tooling.

Tooling lifecycle

Maintenance plans, spare die components and resurfacing services extend tooling life and protect production schedules.

Secondary Operations & Assembly

After extrusion we offer cutting to length, CNC machining of critical faces, drilling, tapping, notching, surface finishing and adhesive bonding. Integrated subassemblies combine extrusions with hardware, thermal components or molded parts for ready‑to‑install modules.

Co‑extrusion & overmolding

Co‑extrusion enables bonding of soft seals to rigid carriers. Overmolding allows extruded seals to be integrated onto housings for single‑piece assemblies.
Secondary Operations & Assembly

Tolerances, Sizes & Typical Specifications

Extrusion tolerances depend on profile complexity, material and post‑processing. Below are representative guidelines used in initial design and costing.

Profile Width

From a few millimeters to several hundred millimeters depending on press capacity

Wall Thickness

As thin as 0.8 mm for aluminum/metal ribs; elastomers typical 1.0 mm and up

Length

Continuous coils or cut‑to‑length up to specified lengths; tight length tolerance for assemblies

Tolerances

Aluminum: ±0.1–0.5 mm post‑extrusion; tightened after machining. Elastomers: ±0.2–1.0 mm depending on feature.

Parameter Range Notes
Materials Aluminum 6061/6063; EPDM, Silicone, NBR, FKM, TPU Select for mechanical, thermal and chemical environment
Surface finish Anodize, powder coat, mill finish Anodize recommended for corrosion resistance and aesthetics
Co-extrusion Yes Soft + rigid combinations for integrated seals and carriers
Prototype lead time 2–4 weeks Dependent on die complexity and material
Quality, Inspection & Traceability

Quality, Inspection & Traceability

We provide dimensional inspection, profile section comparison, tensile/elongation testing for elastomers, and adhesion tests for co‑extruded parts. Process controls include SPC, die verification records and traceable lot labeling for components supplied into regulated supply chains.

Environmental & mechanical testing

Salt spray, UV/aging, compression set, and thermal cycling tests per application requirements.

Applications

Thermal Rails & Heatsink Profiles

Aluminum extrusions with integrated fins and mounting features for passive cooling and thermal management.

gasket

Seals, Gaskets & Weatherstrips

Elastomer extrusions for doors, enclosures, and exposed outdoor equipment with UV and ozone resistance.

plan

Architectural & Trim

Decorative aluminum trims, window frames and custom channel profiles with anodize/color finishes.

Representative Projects

Aluminum Thermal Rail for Power Module

Aluminum Thermal Rail for Power Module

Custom finned extrusion with integrated mounting slots and CNC machined mating surfaces; anodized for corrosion resistance and shipped as kitted assemblies.
Co‑extruded Silicone Seal for Outdoor Enclosure

Co‑extruded Silicone Seal for Outdoor Enclosure

Silicone over rigid carrier for easy installation, UV‑stabilized compound and automated trimming for consistent length and finish.

Frequently Asked Questions

How do I get started with a custom extrusion?
Provide a cross‑section sketch (DXF or DWG) or 3D CAD, target material, expected volumes and required tolerances. We will assess die feasibility and return a tooling and sample plan.
Die cost depends on profile complexity and size. We provide amortization scenarios across expected volumes and optional die ownership/lease programs to reduce upfront cost.
Yes — co‑extrusion for soft seals on rigid carriers or multi‑durometer elastomer profiles is supported; we validate adhesion and process compatibility during prototyping.

Start Your Extrusion Project

Upload your profile cross‑section or STEP file and tell us the material and target volumes. We’ll provide die recommendations, prototyping options and a price/lead time estimate — typically within 24 business hours.
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