We here at V.A.V. Group know what it takes to cater to the needs of both new and existing clients. One of our responsibilities is designing, manufacturing, and testing unique custom-made extrusion dies, or tools, as we call them. 3D printing is a modern and efficient way of making the right extrusion die for the right job.
What is a profile extrusion die?
A profile extrusion die is a custom-made tool used to shape materials, such as silicone and TPE, into a continuous cross-sectional profile.
As the material is pushed through the die, it takes on the exact shape of the opening, allowing for the precise production of items like seals, gaskets, and other industrial profiles.
Silicone profile is then additionally run through an oven so that it will retain its shape.
Meet the brief
One of the key advantages of V.A.V. Group’s process is the seamless integration of in-house metal 3D printing with design expertise. With our engineer Arttu Juntunen at the helm, new tool concepts can be rapidly turned into physical prototypes using the company’s metal 3D printer. This not only accelerates development but also allows for immediate hands-on evaluation of form and fit before any metal tooling is made.
The first step is always understanding the customer’s need for a certain profile. Together with our sales team and the customer’s representative, we gather all the necessary information to see how we could find the right solution. Careful planning is crucial, as that is how we find the right manufacturing process for the profile and calculate the costs of manufacturing. Once the project has been green-lighted, the process itself is relatively swift: within two weeks, we will have designed and 3D-printed the tool and will be ready to make your prototype. Usually, it only takes minor tweaks here and there by hand to reach the final product.
V.A.V. Group works closely with its customers to avoid mistakes. The customer usually knows the basic needs of their new profile – the shape, material, heat resistance, etc. Most customers deliver all the information along with images, blueprints, and measurements, but if those are unavailable or the customer is placing their first order, our salespeople are experts in their field and will help the customer with the specifications.
Custom is the new standard
By printing and testing the extrusion of prototypes on-site, we can significantly reduce sample time and optimize the tools before moving on to full-scale manufacturing. Depending on the tool, the printing will take from one to three days. This streamlined approach shortens the feedback loop and ensures that by the time a tool reaches the production line, it’s already well-refined, minimizing downtime and improving overall production run time. The result is a faster path from concept to tested profile, giving customers quicker access to tailored solutions.
V.A.V. Group has used a 3D printer since 2017, but our custom extrusion dies go back a long way. EDM wire cutters are still relatively common, but the efficiency of a 3D printer is unbeatable. 3D printing is not always faster than EDM wire cutting, but it’s more efficient, as the printer can handle several extrusion dies and does most of the work. All we need to do is make tiny adjustments by hand, and often not even that. The printer is so much more accurate than any welder or cutter. The number of custom tools we have created is in the thousands by now, given that we design around 50 custom tools per year.
Aside from a few staple profiles, every profile is unique and requires its own tool. Even though the term “custom-made” is linked to a higher price tag in consumers’ minds, it’s the complete opposite in B2B solutions. It’s either a custom extrusion die or altering common profiles. By running the quick math, one custom tool that is technically eternal will make every inch of the profile cheaper the more you produce.
How to get your custom profiles
V.A.V. Group has a customer-oriented and flexible approach to profile manufacturing. Learn how to get your bespoke profiles in four simple steps.
