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- We need prototype samples in four to six weeks completely fabricated and anodized. We plan on machining it out of bar stock aluminum because an extrusion die, fab and finish takes too long. Can you do any better? Typically a solid extrusion die can be built
in five days and depending on scheduled backlog a sample run made within
five days (for a hollow add five more days). The parts can then be
run through a model shop, or computer numerically controlled machine
and have fabricated parts within three to five days. The finish probably
adds another two to three days. From idea to sketch to drawing to prototypes
takes less than 20 days, and you have a near-net custom shape plus
a proven process for repeatability. The cost is also relatively low
-- depending on the shape, a 50-piece prototype can cost less than
$2,000 including all the tooling.
- Why is the length such an important factor in determining the price of extrusions? The extrusion process is designed to be
a combination of heat, die and pressure, which forms an extruded shape
from an aluminum billet. The extruder's goal is to increase recovery
from the billet by reducing scrap and obtaining the optimum amount
of quality extruded material from each push (cycle of the extrusion
press). Therefore, potential cost savings exist when extrusions are
purchased in their known end-use lengths, or length multiples, as the
best means to reduce scrap generated in the extrusion process.
- How is the cost determined? Production cost for extrusions is a function
of size, quantity, wall thickness, weight/foot, alloy, temper, length,
packaging, classification of shape (solid, semi-hollow or hollow),
marking and shipping quantity tolerance. When possible, follow the
design suggestions of the extruder to generate the lowest production
cost.
- Can my extrusion be cut shorter at the time it's extruded? Short lengths usually are cut as a secondary
operation. In most cases, the extrusion press produces extrusions faster
than the saw can cut. To cut the extrusions shorter while extruding
would back up the whole operation.
- Can alloy 2024 be extruded? Yes. Some of The Shapemakers can extrude
2024. However, do you really need 2024 or was it simply the alloy used
on the prototype? Make sure 2024 is really the alloy you need, i.e.,
you are specifying 2024 for its specific qualities.
- Can both of my shapes be run through the same die? In almost every case this would be impractical
since the die must be balanced relative to the centerline. Furthermore,
one shape may extrude faster than the other. Since die service charges
are low anyway, it's better to have a die made for each shape.
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FAQ's
