Bespoke Extrusions Die Mould Fabrication & OEM Services
For applications requiring proprietary profile shapes, TS Aluminium designs and fabricates custom extrusion dies. Sourced from high-grade H13 tool steel, our dies are processed inside our workshop using wire electrical discharge machining (EDM) to ensure strict dimensional control.
Extrusion Flow Simulations & Alloy Tempering
Custom profiles with complex hollow channels can fail during extrusion due to uneven metal flow speeds. Our engineers run finite element flow simulations to balance melt speeds through the die openings. Extrusions are processed using structural alloys (6060, 6063, 6061, and 6005) and tempered to T5 or T6 metrics to satisfy structural specifications.
"By maintaining internal machining capabilities, we control every stage of die design and test runs, delivering custom structural profiles in short lead times."
Extrusion Die Production Parameters
| Extrusion Parameter | Target Metric / Limit |
|---|---|
| Extrusion Press Capacity | 1,650 Ton / 2,200 Ton options |
| Dimensional Tolerances | Conforming to AS/NZS 1866 |
| Max Profile Width | 220mm section envelope |
| Mould Steel Hardness | 48 - 52 HRC (Heat treated H13 steel) |
Frequently Asked Questions
How do you verify the quality of custom dies?
Each die undergoes a test extrusion run. The sample profiles are scanned using optical coordinate checkers to log dimensional accuracy.
What is the lifespan of an extrusion die?
A high-quality steel die processes 15 to 30 tons of aluminium billets before requiring refurbishment or nitriding surface treatments.
Can you design dies for hollow multi-cavity profiles?
Yes, we specialize in bridge/porthole dies for complex hollow structures, ensuring consistent wall thicknesses and seam welds.
Related Projects & Case Studies
Virginia OEM Window Extrusion Die
Design and fabrication of a custom three-cavity bridge extrusion die for high-thermal casement window frames.
Pinkenba Commercial Facade Mullion Die
Development of a heavy-duty single-cavity die for structural facade vertical mullions.
Request Engineering Specification
Submit your project dimensions, wind zone parameters, or target specs. Our Slacks Creek team will review and reply within 24 hours.
Standard Operating Protocols & Accuracy Validation
TS Aluminium follows standard operating protocols across all design, extrusion, and machining services to maintain tolerances. For on-site spatial measurement, our Faro 3D laser scanners collect spatial coordinates to map site features within a sub-millimeter margin of error. The spatial scan is registered into a single coordinate system, which is then imported into AutoCAD and SolidWorks to design structural joints that fit site conditions exactly.
For custom die mould manufacturing, we use melt flow simulations (Finite Element Analysis) to evaluate polymer/metal flow rates under extrusion pressures (up to 2,200 tons). This simulation prevents die deformation and ensures wall thicknesses comply with the allowable limits defined in AS/NZS 1866. For multi-axis CNC routing, tool paths are generated using CAD/CAM systems that set spindle speeds and feed rates (e.g., 18,000 RPM spindle speed with a feed rate of 3.2 m/min for 6061-T6 profile machining).
Our installation teams follow concrete anchoring protocols. Chemical anchoring epoxies require a full 24-hour cure duration at 25° C before structural loads are applied. Once installed, sliding sashes, EPDM seals, and latch hardware are adjusted using digital gauges to verify smooth operation and watertight seals, ensuring long-term durability.