The Extrusion Process Explained: From Pellets to Profiles

Plastic extrusion may seem simple at first glance — melted plastic shaped into a continuous profile — but behind that simplicity lies a finely tuned process built on precision, consistency, and performance.

At Lincoln Plastics, every part we make begins with the same foundation: quality materials, reliable processes, and a focus on the customer’s application. Here’s how the extrusion process transforms raw plastic pellets into durable, dependable components.

Step 1: Material Preparation

It all starts with thermoplastic pellets — the raw material that defines the performance of the final product. Each resin is carefully selected based on the customer’s requirements, such as flexibility, UV resistance, or impact strength.

Some resins require drying or conditioning before production to remove moisture and ensure consistent melt quality. Others are processed directly, depending on the material’s formulation and intended use.

Step 2: Melting and Extrusion

Pellets are fed into an extruder, where a rotating screw pushes them through a heated barrel. As the material melts, it’s mixed and homogenized before being forced through a custom-designed die — a precision tool that shapes the profile.

From flat channels and protective covers to conduit-style extrusions, the die design defines the function. Every die we build is engineered to meet the exact dimensional and performance needs of our customers.

Step 3: Cooling and Sizing

Once the plastic exits the die, it’s still soft and formable. The newly shaped profile enters a controlled cooling process, often water-based, that stabilizes its dimensions and locks in its final shape.

This stage is critical — proper cooling ensures straightness, uniform wall thickness, and dimensional accuracy.

Step 4: Cutting, Coiling, or Finishing

After cooling, extrusions are cut to specific lengths, coiled, or packaged depending on the product’s application. Throughout production, our team performs in-line and post-run inspections to confirm that every part meets specifications for size, shape, and quality.

Step 5: Packaging and Delivery

Once approved, parts are packaged and prepared for shipment — whether heading to a local customer or across the country. Our goal is to deliver every order on time, on spec, and ready for installation or assembly.

At Lincoln Plastics, decades of experience go into every extrusion we make. Our process combines expertise, precision tooling, and attentive quality control — helping OEMs build better products from the ground up.

Contact us today to learn how we can support your next extrusion project.

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