Extrusion International 3-2026

29 Extrusion International 3/2026 EXTRUSION TOOLING Getting the Most from Your Extrusion Tooling Tooling maintenance improves extrusion ef ciency, enhances quality and boosts overall productivity for your medical tubing applications. By: Glen Guillemette, President Guill Tool & Engineering B y utilizing state-of-the-art production equipment and processes, machining tolerances are held ex- tremely close on today’s multi-lumen and multi-layer medical tubing. It is important to note that any mis- alignment of the tools may be exaggerated in the nal product output. Clean parts, especially with sealing and locating surfaces, are key to product performance and successful end products. These surfaces receive the most care and attention during manufacturing and are the control surfaces that ensure uniformity throughout the tubing. Remember, precision-machined alignments are affected by even a speck of dirt measuring only a few thousandths of an inch. A human hair is about 0.003" (0.08 mm), and since there are many such surfaces in a quality tool, cleanliness is critical. Checking of the tools for any deformities is also im- portant. Burrs, scratches and scrapes are usually a re- sult of careless handling and/or storage of equipment. Double and triple-layer extrusion heads pose an even greater challenge for maintenance. The number of sealing and centering surfaces multiplies and can mag- nify the results of dirty tools. During changeovers, the head may be disassembled in order to change com- pounds and/or tips and dies. Foreign matter is usually introduced at this point and residual materials must be thoroughly removed. Physical tool damage often occurs during this phase, due to mishandling and poor storage techniques. These are highly precise parts, but can also be heavy and bulky to remove by hand. Use of a dedicated work cart exclusively reserved and equipped for extruder head maintenance is rec- ommended. This cart along with a supply of spare components and hardware is easily justified, especial- ly when examining the potential cost savings that re- sult from well-maintained tools. The following should be considered: 1.) Maintain a clean, organized work area with soft and clean renewable work surfaces 2.) Use a vise with soft jaws, such as copper 3.) Use special equipment, such as tip removal tools, etc. 4.) Standard tools include wrenches, soft-faced ham- mers, etc. 5.) Maintain a supply of soft, clean rags. 6.) Use cleaning solutions in spray bottle. 7.) Use spare parts as suggested by your tooling sup- plier, properly organized and stored. 8.) Keep handy your equipment’s repair/maintenance manual. 9.) Have a small surface plate to provide a true at sur - face. 10.) Use a set of appropriate gauge and tip pins for initial tool location adjustment. 11.) Make sure you have all the proper lifting aids available, including overhead hoists, hydraulic lifts, etc. In most situations, the head and tooling will still be at elevated temperatures, therefore lined gloves are need- ed when handling. Today, tubing manufacturers compete with companies all over the world. To be a successful and pro table com - pany, quality and ef ciency are essential. This is especially true in extrusion, where material costs are usually much higher than labor costs. Like a racing car stuck in the pit, many extruders sit idle because of poor or damaged tool- ing, plus excess maintenance time. Overhead costs add up and losing money is the result. Some start up quickly and make scrap, whereas others start up and run a prod- uct oversized to hold minimum tolerance. They waste 10 to 20% of the material, which can run from 50 to 90% of the product cost. The tooling supplier goes to great lengths so that tips and dies are machined to a deter- mined speci cation, ensuring perfect concentricity and alignment. The material is then distributed in the proper location as part of the nished product. Understanding Maintenance Procedures: Get Organized Before You Start Example 1: In this example, with an improperly cen- tered tool, a calculated out-of-tolerance area of 0.059