Extrusion International 3-2026

30 Extrusion International 3/2026 EXTRUSION TOOLING in2 (38 mm2) was derived. When the two surface ar- eas were compared, the calculated material waste was 11.8% of the nished product. The formula is % wall = min. wall thickness, max. wall thickness X 100. Example 2: Alternatively, if the % wall can be in- creased from 80 to 95%, a savings of about 12% of total cost can result. Savings will vary depending on the de- signs, of course. Get help for heavy parts and awkward situations. Sur- faces and edges are hard and therefore somewhat brit- tle, so dropping a part or striking parts together can re- sult in damage. Store your tools properly in a dry, clean area – a dedicated spot for each tool is best. These areas should have soft surfaces and each instrument should be covered after cleaning. Also, tools should be segre- gated so that they do not come into contact with each other. And tools and all instruments should be cleaned thoroughly before storage. For disassembly of tools, it is imperative to use pur- pose-built tooling to facilitate disassembly. These should be available from your supplier. If they are not, consult with a reputable tooling house for replacements. The cost of these tools is easily offset by potential damages, frequently caused by improper equipment such as ham- mers and drifts. Follow the guidelines outlined in your operator’s manual. Individual tools may have speci c recommendations, so contact your supplier if anything is unclear. Your supplier understands that optimum per- formance relies on proper care and maintenance. Here are some useful tips: 1.) Clean your equipment while it is still hot as the residue is easier to remove. It helps to remove and clean one piece of tooling at a time in order to maintain el- evated temperatures. 2.) When cleaning a dual compound crosshead, (plas- tic and rubber) clean the plastic tooling rst; the rubber second. 3.) Never use steel tools such as scrapers or screwdriv- ers because these can scratch and mar the tooling. 4.) Don’t use open ames because this generates ex - cessive heat especially in thin sections, which can affect hardness, concentricity and tolerances of components. Recommended cleaning tools and materials include: a.) Brass pliers to grip material and aid in pulling b.) Brass scrapers available in different widths for cleaning at exposed surfaces c.) Brass bristle tube brushes that are available in di- ameters from 1/16" to 1" in 1 /16" increments (ideal for cleaning holes and recesses) d.)Brass rods—different diameter rods are good for pushing material out of ow holes e.) Copper gauze for cleaning and polishing exposed round or conical surfaces f.) Copper knives for removing residue from recesses and other hard-to-reach areas. Also, polishing com- pound restores polished surfaces g.) Compressed air, which is more effective for releas- ing plastic, but also aids in rubber removal. Be careful not to force debris into recesses with compressed air h.) Cleaning solutions may be useful, so remember to use fresh, clean rags (used rags often have metal chips embedded in them, which may scratch polished surfaces) i.) Cleaning oven – for plastic only. Follow manufac- turer's recommendations. If no temperatures are speci- ed do not exceed 850 degrees F (454 degrees C). Don’t quench tooling to cool, as this could affect tooling hard- ness, concentricity and tolerances. j.) Purging compounds – several are offered to purge the extruder screw/barrel of residual polymer and rub- ber compounds Removing Excess Material for Optimum Machining Ef ciency Clean parts are critical to extrusion tooling perfor- mance and quality manufacturing. This is especially true for the sealing and locating surfaces – that control uni- formity of the production process. For general mainte- nance of the tools, before storage or tooling change- over, a thorough cleaning and removal of the excess material assures the precision machining alignments required to produce end prod- ucts to the precise tolerances. Equipment should be cleaned while it is still hot, since residual polymer and rubber will be easi- er to remove. Be sure to follow all MSDS recommendations when heating the tooling. Thermal gloves are used to protect the hands from the heated tooling surfaces. A brass scraper, as well as a brass or