Thermoplastics Extrusion
The Art of Extrusion – Forming, Designing, Optimizing
Thermoplastics Extrusion
Innovative material blends and outstanding technical properties that go far beyond the conventional: We process compounds with short or long fibers made from various materials such as glass, carbon, or minerals—even those with high filler content. This allows us to go far beyond the realm of possibility.
These advanced compounds enable exceptional properties, including thermal or electrical conductivity, UV resistance, and micro-hollow chamber profiles tailored for specialized applications. Leveraging our proprietary extrusion technology, we process these materials with outstanding precision. The result: ultra-smooth surfaces, sharp contours, the tightest tolerances, and the highest precision.
Interview with Konal Khurana, Purchasing Manager, and Philipp Sälzer, Research & Development, at Technoform
Konal, Technoform has more than 50 years of experience in extrusion. What sets your manufacturing process apart from the rest?
Konal: We specialize in producing thermoplastics. Continuous extrusion is the standard method for producing profiles from thermoplastic materials. Using other manufacturing processes, such as milling or injection molding, to manufacture products of this type would not be cost-effective.
Konal Khurana
Apart from the applied technology, what else makes Technoform unique?
Konal: As well as extruding, we advise our customers in relation to product development. We design solutions for a vast range of industries, which is what sets us apart from other extrusion companies. Technical experts are involved in our customers’ R&D projects at a very early stage; this way, they can cater to individual requirements and assess the feasibility of their ideas. We offer not only offer application expertise but also expertise in material processing.
Our ability to design extruding dies in-house is a crucial factor here, as it allows us to create dies tailored to the needs of each customer. Our advantage here is simply that we are extremely well-versed in our trade.
What materials are you able to extrude?
Konal: We specialize in extruding thermoplastic profiles made from polypropylene, polyamide or polyphenylene sulphide (PPS) with a reinforcement material, such as glass fiber, and other additives to achieve the customer’s desired function, for example UV protection, low thermal conductivity or corrosion protection. Thermoplastics can also be recycled and remelted any number of times, which makes them a more sustainable material option compared with other plastics.
Material meets form:
How important is material selection?
Konal: It’s very important for the efficiency and the quality of the extrusion process. The main thing to consider when selecting a material is what properties the product needs to have in its final application. In other words, a precise specification of the required material properties reduces the risk of obtaining varying extrusion results although supposedly using the same materials.
The important thing is for the quality to be consistent! This is the only way to avoid having to change the production parameters at the extrusion line and to ensure the quality of the profiles.
Otherwise the profiles may have a defective form, be difficult to process or have defects that are only discovered in the mechanical tests following extrusion. The material therefore has a major impact on the efficiency of the process.
For this reason, our R&D teams test how new materials react in combination with our manufacturing process and the customer’s die before they are approved.
How long does it take to switch to a new material?
Philipp: We introduce new materials on the basis of product-specific requirements. Approval procedures are sometimes complex, for example in the construction industry, so material approvals can take a relatively long time.
Recycling materials have become particularly important, in the form of post-industrial recycling (PIR) and post-consumer recycling (PCR) materials. We work closely with our customers and suppliers to create sustainable solutions that reduce the impact on the environment and the climate.
What factors do you take into account when procuring material?
Philipp: Our interest is always in finding the best solution. As we have a broad product portfolio, in order to fulfil the needs of global customers, we focus particularly on reliable suppliers and high-quality materials. Corresponding national standards and regulations need to be complied with, for example EU requirements, the REACH Regulation and other certificates such as cradle-to-cradle (C2C). Since COVID-19, we have started to focus more on minimizing risks and having multiple material sources with proven quality and reliability. The aim here is to establish long-term partnerships. Social issues are also an important criterion for us, as we believe people should be treated fairly and that nature should be respected.
The future of extrusion:
What technologies or materials are set to change extrusion?
Philipp: The developments in extrusion are dependent on what the market needs – sustainable and effective construction, for example, or products with better sustainability scores.
We are currently using 3D printing as a fast alternative for producing samples and prototypes. Although 3D printing has not yet reached its full potential and cannot achieve the same precision and efficiency as our extrusion processes, we are investigating other ways it could be used. 3D printing also has potential in die construction. It could allow parts to be produced that would not be possible using conventional production methods.
Customers can also benefit from new types of tooling steel that increase the service life (durability) of dies and open up new possibilities for profile design. Long service lives are also advantageous in series production, as this can save costs and time.
In the future, a system for recycling materials will need to be set up. This switch to a sustainable material process that conserves resources will pose new challenges for producers.
When it comes to sustainability, however, the material that is used is the key factor. More sustainable raw materials will be required.
What role will digital twins or simulations play for extrusion in the future?
Philipp: A digital twin is a virtual model of a physical object or system that uses real-time data to simulate the behavior of its real-life counterpart. These models can be used in various phases of the product’s life cycle, from development to maintenance.
The digital twin is a representation of a material or immaterial object from the real world in the digital world. It can be used on any systems or devices, and offers more simulation options than conventional methods, enabling multiple scenarios to be depicted at the same time and supplies more precise results.
Thanks to data analysis and machine learning, digital twins can make predictions and suggest optimizations. This makes it easier to identify bottlenecks and optimize the use of resources. As a result, materials can be used more efficiently and produced more sustainably, supporting our goal of achieving a closed-loop recycling system.