What is a custom profile extrusion?

Plastic extrusions can be found just about anywhere you look — in cars, homes, and even our cell phones. These plastic components sit inside our everyday products, helping them seal better, look better, last longer, and function safely. But not all plastic extrusions are created equal. Some are made from a stock profile die and mass-produced with standard material; others use customized profile design, custom tooling, and specialty plastics to achieve the right shape and function for the end product being made.

When stock profiles work, and when they don't

There are plenty of off-the-shelf profile dies available for standardized applications. The piping trim found on many couches and pillows, for example, uses a mass-produced stock profile called a welt cord — fabric is wrapped around a lightweight, cylindrical welt cord extrusion to create a sturdy, uniform, long-lasting trim that's still comfortable to sit on. That extrusion's versatility means it can be made and sold off-the-shelf for any size of cushion, and it can use a standard plastic because it doesn't require special properties to perform.

As you might imagine, there are many cases where a standard profile shape or material won't work. That's where custom profiles come in.

The process behind custom profiles

Custom profiles are thermoplastic extrusions made with a custom profile shape. Custom tooling is designed to achieve unique specifications, and once the profile is created and tested for quality, it can be used to produce large lots of extruded components.

In the custom profiling process, a multitude of specialized plastics are available, each offering a different range of material properties. Choosing the right plastic improves function and extends the life of your product — some stand up to extreme temperatures and high humidity, while others are known for resisting chemical exposure and UV light.

When a standard shape or material won't do the job, a custom profile is engineered to fit your exact application.

When to opt for custom profiling

The need for a custom profile can arise at any point during production. Some manufacturers know in the early design phases that a custom profile will be needed because they're designing for unique circumstances or proprietary products that require innovative — and sometimes complex — plastic configurations.

Others turn to custom profiling to optimize part performance — for example, when a specific plastic component in a car is failing to keep the battery from shorting out. In cases like that, it can be worth starting from the drawing board and pursuing a new custom profile design for production.

Finding the right custom profile partner

It's important to find a custom profile partner you can trust — one with real expertise in advanced materials and tooling. Our team at Custom Profiles uses the industry's latest design tools along with creative engineering to find innovative thermoplastic extrusion solutions for everyone we partner with. Connect with us today to learn more about the custom profile process and how we can help on your next project.