If your product includes long, consistent shapes — like rails, tubes, housings, or channels — extrusion is a highly efficient way to produce them. It’s especially useful for lightweight structural parts, and often used in aluminium and various plastics.
At Everlab, we design parts specifically for extrusion and guide you through the process, from smart geometry to compatible post-processing. While we don’t extrude materials in-house, we work closely with experienced partners to get it right.
What is extrusion?
Extrusion is a production method where heated material (usually aluminium or plastic) is pushed through a die to create a continuous shape — like squeezing toothpaste from a tube, but with precision and purpose.
Once cooled, the material is cut to length and often drilled, milled, anodized, or coated afterwards.
Why choose extrusion?
- Efficient for long, uniform shapes
- Cost-effective in medium to large quantities
- Excellent strength-to-weight ratio (especially in aluminium)
- Clean, professional appearance
- Works well with secondary operations (like anodizing or machining)
Common applications
Extrusion is a great choice for:
- Frames and enclosures
- Rails, tracks, and guides
- Heat sinks
- Tubes and hollow profiles
- Functional decorative trims
When it makes sense
We often recommend extrusion when:
- Your part has a consistent cross-section
- You need precise length and good straightness
- Weight reduction is important (e.g. aluminium frames)
- You’re ready for a dedicated die investment for scalable production
Custom tooling (a die) is usually required, but the payback is fast if you’re making more than a handful of parts.
How we support extrusion
We can:
- Design extrusion-friendly parts, with proper wall thicknesses, tolerances, and uniform cross-sections
- Help select the right material and finish
- Prepare drawings for production and finishing
- Coordinate with extrusion and finishing partners for reliable delivery
Have a shape that runs the distance? Let’s extrude it.
