Design is one of the most critical aspects of any manufacturing process. A design that has addressed all of the nuances of your product helps ensure a smooth production run, minimizes defects, and in some cases, can even speed up cycle times, which gets your product to market faster.

Port Erie Plastics has solved numerous plastic extrusion design challenges, and there are some best practices we’ve picked up on over the years. Keep this guide in mind as you look to maximize your extrusion design ahead of your next project.

Plastic Extrusion Design Starts With a Focus on the Cross Section

The cross section in any extrusion design is arguably the most critical aspect to get right. Cross sections are what give the final product its shape and require consistency. To ensure the cross sections are in the best shape possible, keep these considerations in mind.

• Keep wall thickness as uniform as possible. When wall thickness is consistent throughout the cross section, unequal flow, differential cooling, bowing, distortion, and other defects are kept in check.
• In tandem with wall thickness consistency, if the thickness has to change, attempt to make it gradual rather than abrupt.
• Rounded corners are preferred compared to sharp corners, as rounded corners are better at limiting notching and cracking.

Carefully Design Hollow Points and Internal Features

There are naturally going to be hollow points inside any extrusion design, and because of that, the potential for defects is much greater than in denser sections. With that in mind, these pointers can be helpful during the design phase.

• Keep hollow sections as simple as possible. The more complex hollow sections and internal features are, the more likely they are to distort during the extrusion process.
• If internal features are necessary for your product’s intended application, consider adding access points such as windows or slots in order for legs, grooves, or other support measures to reach the internal features.

Control Tolerances

Every manufacturer has different levels of tolerances they can provide, so when you have landed on the company that’s going to produce your extruded parts, be sure to have a conversation with their engineering team about tolerances throughout your plastic extrusion design. In general, it’s best to have relaxed tolerances wherever possible. The tighter a tolerance, the more tooling work and costs you’re likely to incur.

Remember, Material Selection Is Part of Design Considerations

Design isn’t just drawing up the blueprint to your product. It’s also having an intimate knowledge of how your component is supposed to function in its environment. While the above tips and considerations are intended to have all of those points in mind, the largest aspect of design that’s impacted by outside influences is the material itself.

Align materials that match the mechanical needs, environmental factors, and regulatory constraints of both the manufacturer and your respective industry, while being extrusion-friendly. This is where your manufacturer’s engineering team can be extremely helpful.

While most extrusion projects can be completed with just a single material source, for more complex jobs, consider blending materials into one uniform product via co-extrusion.

Connect With Port Erie Plastics to Best Enhance Your Plastic Extrusion Design

Port Erie Plastics is your full-service plastic manufacturer with wide-ranging capabilities, including plastic extrusion services. Plastic extrusion design is one of the most critical aspects of the manufacturing process, and getting the design right helps eliminate defects and sets up an easier production cycle.

Our engineering team has worked on numerous extrusion projects over the years, and we continue to work with our customers throughout the process to ensure their designs are set for manufacturing.

Have a question or concern about your plastic extrusion design? Contact Port Erie Plastics today, where we’ll work out the details and create a product that’s built to last.