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Custom Extrusion Guides
Start from the cross-section and material. The die, wall distribution and straightness requirements determine whether a profile is economical to extrude.
Updated October 11, 2026 · 14 focused articles
Find the guide for your next decision
Follow the guide that matches the feature, failure mode or project decision you are working on.
Profile Extrusion: What the Die Decides and What the Customer Controls
What the Die Decides and What the Customer Controls
Extruded Plastic Profiles: Reading a Section Drawing Like a Die Designer
Reading a Section Drawing Like a Die Designer
Custom Extrusion Plastic: Turning a Section Idea Into a Die and a Delivery
Turning a Section Idea Into a Die and a Delivery
Co-Extruded Plastic Profiles: Two Materials, One Die, One Continuous Length
Two Materials, One Die, One Continuous Length
Aluminum Extrusion Process: From Billet and Die to Finished Profile
From Billet and Die to Finished Profile
Aluminum Extrusion Design Rules: Wall Thickness, Tolerances, and Profile Complexity
Wall Thickness, Tolerances, and Profile Complexity
Extrusion for Heat Sinks and LED Enclosures: Thermal Profiles That Work
Thermal Profiles That Work
Extrusion Prototypes and Low-Volume Runs: When Extrusion Dies Make Sense
When Extrusion Dies Make Sense
Plastic Extrusion for Custom Profiles: Materials and Applications
Materials and Applications
Secondary Machining for Extruded Profiles: Cutting, Drilling, and Assembly
Cutting, Drilling, and Assembly
Aluminum Extrusion Tolerances: Standards, Classes, and What to Specify
Standards, Classes, and What to Specify
Aluminum Extrusion vs CNC Machining from Bar Stock: How to Choose
How to Choose
Plastic Extrusion Tolerances and Material Behavior for Custom Profiles
Read the focused guide for plastic extrusion tolerances and material behavior for custom profiles.
Aluminum Extrusion Tolerances: What the Die and the Alloy Decide
What the Die and the Alloy Decide
Before you release the project
- Define the function, environment and the question this batch must answer.
- Specify material grade, geometry, quantity, finish and the dimensions that control fit.
- Agree the inspection method and the evidence required to accept the parts.
- Record the drawing revision and approval before production begins.
Common planning questions
What drives a custom extrusion decision?
Cross-section geometry, material, expected length and quantity, die complexity, straightness and finishing requirements are the main inputs.
Which dimensions should be controlled first?
Identify the dimensions that govern assembly and function, then agree achievable tolerances for the profile and any subsequent machining.
Move from guidance to a reviewed project
Send the CAD model and drawing with material, quantity, finish and inspection requirements. Use the relevant service page to review the available manufacturing route.