Browse Topic: Extrusion

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Tolerances Titanium and Titanium Alloy Extruded Bars, Rods, and Shapes AMS2245D (Current)12/9/2025
This specification covers established manufacturing tolerances applicable to titanium and titanium alloy extruded bars, rods, and shapes. These tolerances apply to all conditions, unless otherwise noted. The term "excl" applies only to the higher figure of the specified range.
AMS G Titanium and Refractory Metals Committee
Aluminum Alloy, Extruded Wide Panel Profiles (7150-T77511), 6.4Zn - 2.4Mg - 2.2Cu - 0.12Zr, Solution Heat Treated, Stress-Relieved, Straightened and OveragedAMS4325B (Current)11/21/2025
AMS4325A prohibits unauthorized exceptions (3.7), revises condition (3.2), properties (3.4.5), quality (3.5.1), reports (4.4.1), and identification (5.1.1), and results from a Five-Year Review and update of this specification.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extrusions, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-O), AnnealedAMS4160K (Current)11/13/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extrusions 4.5Cu - 0.85Si - 0.80Mn - 0.50Mg (2014-T6) Solution and Precipitation Heat TreatedAMS4153N (Current)11/13/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing up to 32 square inches (206 cm2) in area (see 8.5).
AMS D Nonferrous Alloys Committee
Maximizing the Potential of TPU Extrusion in Medical Tubing ApplicationsTBMG-5216412/1/2024
Whether for vascular catheters or implantable devices, medical tubing must meet tough standards for flexibility, strength, and biocompatibility. That’s why more manufacturers are turning to thermoplastic polyurethanes (TPUs) that strike the ideal balance between these key properties, making them an excellent choice for high-performance medical tubing. Unlocking the best that TPUs have to offer means optimizing the extrusion process. This article looks at why TPUs are a top pick, the common obstacles in extrusion, and the ways manufacturers can fine-tune their process to get the most out of different grades.
Multiphysics Simulation of Electric Motor NVH Performance with Eccentricity2021-01-10778/31/2021
With the emphasis of electrification in automotive industry, tremendous efforts are made to develop electric motors with high efficiency and power density, and reduce noise, vibration and harshness (NVH). A multiphysics simulation workflow is used to predict the eccentricity-induced noise for GM’s Bolt EV motor. Both static and dynamic eccentricities are investigated along with axial tilt. Analysis results show that these eccentricities play a critical role in the NVH behavior of the motor assembly. Transient electromagnetic (EM) analysis is performed first by extruding 2D stator and rotor sections to form 3D EM models. Sector model is duplicated to form full 360-degree model. Stator is split into three rotated sections to characterize stator skew, and the skew between two sections of rotor and magnets are also modelled. Sinusoidal current is applied and lumped-sum forces on each stator tooth are computed. Next, full 3D structural model is constructed, and EM forces are applied as
Zhang, Henry, Jaura, Ankur, Kumar, Dinesh, Sambharam, Tushar, Zhang, Zheming, He, Song, Zhang, Peng, GSJ, Gautam
Bar, Rod, and Shapes Produced from 30% Glass Fiber Filled Polyamide-Imide (PAI) MaterialAMS3670/4D (Current)5/19/2021
This specification covers molded or extruded bar, rod, and shapes produced from a polyamide-imide (PAI) polymer filled with 30% glass fiber. This is designated as Grade 4 material per AMS3670.
AMS P Polymeric Materials Committee
Molded or Extruded Bar, Rod, and Shapes Produced from 20% Graphite – 3% Polytetrafluoroethylene (PTFE) Filled Polyamide-Imide (PAI) MaterialAMS3670/2C (Current)5/19/2021
This specification covers molded or extruded bar, rod, and shapes produced from a polyamide-imide (PAI) polymer filled with 20% graphite and 3% polytetrafluoroethylene (PTFE). This is designated as Grade 2 material per AMS3670.
AMS P Polymeric Materials Committee
Bars, Rods, and Shapes Produced from Unfilled Polyamide-Imide (PAI) MaterialAMS3670/1C (Current)5/19/2021
This specification covers an unfilled polyamide-imide plastic in the form of molded or extruded bar, rod, and shapes. This is designated as Grade 2 material per AMS3670.
AMS P Polymeric Materials Committee
Bars, Rods, and Shapes Produced from 30% Carbon Fiber Filled Polyamide-Imide (PAI) MaterialAMS3670/5D (Current)5/19/2021
This specification covers molded or extruded bar, rod, and shapes produced from a polyamide-imide polymer filled with 30% carbon fiber. This is designated as Grade 5 material per AMS3670.
AMS P Polymeric Materials Committee
Bar, Rod, and Shapes Produced from 12% Graphite - 3% Polytetrafluoroethylene (PTFE) Filled Polyamide-Imide (PAI) MaterialAMS3670/3C (Current)5/19/2021
This specification covers molded or extruded bar, rod, and shapes produced from a polyamide-imide (PAI) polymer filled with 12% graphite and 3% polytetrafluoroethylene (PTFE). This is designated as Grade 3 material per AMS3670.
AMS P Polymeric Materials Committee
Vote for Medical Design Briefs Product of the Year 2020TBMG-3829012/1/2020
Each month, the editors of Medical Design Briefs choose a Product of the Month that has exceptional technical merit and practical value for MDB’s design engineering readers.
The Benefits of Embedding Marker Bands vs. SwagingTBMG-371266/1/2020
In order to identify the location of a catheter tip under fluoroscopy, the use of marker bands is commonplace in medical applications. These bands are typically platinum iridium metals that are easily detectable on the technology used during the surgeries but can also be made of tantalum or gold for certain applications. The marker bands are put on the catheter, either through swaging or embedding, as a shiny indicator to the surgeon of directly where in the body the tip is located as the operation progresses.
Nanostructured Rubber-Like Material to Replace Human TissueTBMG-368295/1/2020
In the development of medical technology products, there is a great demand for new naturalistic materials suitable for integration with the body. Introducing materials into the body comes with many risks such as serious infections. Many of the substances used today are very toxic, so there is a need for new, more adaptable materials.
Experimental Investigation of Axial Cutting of AA6061 Extrusions under a Tension Deformation Mode2020-01-02064/14/2020
A plethora of applications in the transportation industry for both vehicular and roadside safety hardware, especially seatbelts, harnesses and restraints, rely on tensile loading to dissipate energy and minimize injury. There are disadvantages to the current state-of-the-art for these tensile energy absorbers, including erratic force-displacement responses and low tensile force efficiencies (TFE). Axial cutting was extensively demonstrated by researchers at the University of Windsor to maintain a stable reaction force, although exclusively under compressive loading. A novel apparatus was investigated in this study which utilized axial cutting under a tensile loading condition to absorb energy. A parametric scope was chosen to include circular AA6061 extrusions in both T4 and T6 temper conditions with an outer diameter of 63.5 mm and wall thickness of 3.18 mm. The experiments were performed quasi-statically utilizing a custom, hydraulically powered long stroke tension/compression
Gudisey, Anthony, Altenhof, William, Magliaro, John
Looking to the Future of the Medical Tubing SectorTBMG-364224/1/2020
The future of the medical tubing sector is highly dynamic, not least because there are a variety of pressures on organizations within this area to provide solutions that are not only of the highest quality but also deliver cost savings throughout the product life cycle. This is mainly driven by the global healthcare market, which continues to demand products and solutions that push the boundaries of what is possible at a highly competitive price.
Reducing Risk with Geometric Transition ExtrusionTBMG-3549811/1/2019
In an effort to design smaller, more intricate and complicated medical devices without running afoul of increasingly stringent national and international regulations, many designers are looking to geometric transition extrusions manufactured of high consistency rubber (HCR) silicone. This process reduces total cost of ownership for the original equipment manufacturer while improving part quality and greatly enhancing the types of devices being sought by healthcare providers.
Polyamide Type 6-6, Plastic Moldings and ExtrusionsAMS3617F (Current)6/13/2019
This specification covers one type of Polyamide Type 6-6 (nylon) thermoplastic resin in the form of moldings and extrusions.
AMS P Polymeric Materials Committee
Lattice Boltzmann Simulations of Flow Over an Iced Airfoil2019-01-19456/10/2019
This paper presents an aerodynamic degradation study of an iced airfoil, using the Lattice Boltzmann approach with the commercial software PowerFLOW. Three-dimensional numerical simulations were performed with an extruded constant section of the GLC-305 airfoil with a leading-edge double-horn ice shape using periodic boundary conditions. The freestream Reynolds number, based on the chord, is 3.5 million and the Mach number is 0.12. An extensive comparison of the main flow features with experimental data is performed, including aerodynamic coefficients, pressure coefficient distributions, velocity and turbulence contours along with its profiles at several positions, and stagnation streamlines. The drag coefficient agrees well with experiments, in spite of a small shift. Two different wind tunnel measurements, using different measurement techniques, were compared to the CFD results, which mostly stayed in between the experimental data. Velocity and turbulence intensity contours as well
Ihi, Rafael, Ribeiro, Andre, Santos, Luis, Silva, Daniel
A Comparison of the Mechanical Performance of AA6061-T6 Extrusions Subjected to Axial Crushing and Axial Cutting2019-01-10944/2/2019
Conventional axially loaded energy absorbers dissipate kinetic energy through progressive folding. The significant fluctuations in load and high risk of transition to global bending are drawbacks that engineers have attempted to mitigate through several methods. A novel energy dissipation mechanism, referred to as axial cutting, utilizes thin-walled extrusions and a strengthened cutting tool to absorb energy in an axial impact. Compared to progressive folding, this can be achieved with minimal fluctuations in load during the deformation process. Based upon estimates from finite element models, a series of test cases were postulated where, for 8 and 10-bladed cutting scenarios, greater total energy absorption could be achieved through axial cutting than with progressive folding of geometrically similar extrusions. The specimens were AA6061 extrusions having T6 temper conditions that possessed 63.5 mm outer diameters and 1.5 mm wall thicknesses. All tests were performed quasi-statically
Magliaro, John A., Altenhof, William
Estimation of Cutting Parameters in Two-Stage Piercing to Reduce Edge Strain Hardening2019-01-10924/2/2019
Edge fracture is a common problem when forming advanced high strength steels (AHSS). A particular case of edge fracture occurs during a collar forming/hole extrusion process, which is widely used in the sheet metal forming industry. This study attempts to relate the edge stretchability in collar forming to the strain hardening along the pierced edge; thus, Finite Element (FE) simulations can be used to reduce the number of experiments required to improve cutting settings for a given material and thickness. Using a complex-phase steel, CP-W 800 with thickness of 4.0 mm, a single-stage piercing operation is compared with a two-stage piercing operation, so called shaving, in terms of strains along the pierced edge, calculated by FE simulation. Results indicated that strains were reduced along the pierced edge by shaving. These results are correlated with experimental observations made at the Technical University of Munich (TUM) where better hole expansion ratios (HERs) were obtained using
Diaz-Infante, David, Narayanan, Advaith, Altan, Taylan
Ruggedizing Commercial-Grade Computers into MIL-Hardened Systems19AERP02_012/1/2019
As performance capabilities for embedded computing products expand, the requirements for commercial-grade and MIL ruggedized systems blur into similar specifications. There are increasing demands to take feature-rich, successful industrial/commercial enclosure systems into MIL or other harsh environment applications. Similarly, engineers are designing up-front computing platforms that they can expand into harsher environments.
Aluminum Extrusions Help Ski Maker Achieve Olympic-Sized GoalsTBMG-336902/1/2019
Minalex Corp. Whitehouse Station, NJ
Large-Volume Extruder for 3D PrintersTBMG-335951/1/2019
A low-cost 3D bioprinter was built by modifying a standard desktop 3D printer with a syringe-based, large volume extruder (LVE). The extruder works with most open-source fused deposition modeling (FDM) printers.
Metal Tubing Offers Flexibility for Disposable DevicesTBMG-3325811/1/2018
Traditional handheld surgical tools continue to provide benefits where surgeons need instruments to be more rigid and have strong holding power to withstand complex procedures. The majority of these small handheld devices include tubing technology. Those made with metal can be formed to meet specific needs. Base tubing can be created from drawn tubing or from flat sheets of metal in a patented technique known as rolled-tube technology, which is ideal for creating high volume disposable devices.
Ensuring Injection Molding Quality for Medical DevicesTBMG-3308910/1/2018
Plastics are incredibly versatile. There are thousands of types available to satisfy a myriad of medical applications. Yet, certain plastics present special challenges during the injection molding process that — if not properly addressed — can impact product quality and ultimately preclude medical devices from meeting exacting specifications. The medical device or component cannot — and must not — fail. To do otherwise increases the risk of recall, warranty claims, and litigation. In worst-case scenarios, failure may prove lethal.
Tests Prove Immersion Method of Production of Implantable Devices is EffectiveTBMG-328189/1/2018
Healthcare-associated infections (HAI) are a major, yet often preventable threat to patient safety, and they can have a significant impact on the survival rate of patients who undergo procedures and treatments. In particular, catheter-associated infections are difficult to prevent, even when products are made of silicone, due to their inherent positioning both inside and outside of the body.
Strain-Life Fatigue Data File FormatJ2409_201808 (Current)8/24/2018
SAE format for a SIMPLE Strain-Life Fatigue Data Exchange File Format. The object of this SAE Standard is to provide a simple common way to exchange strain-life fatigue data collected from ASTM E 606 axial fatigue test data.
Materials, Processes and Parts Council
Two-Component Molding Can Solve Medical Design Challenges and Reduce CostsTBMG-289255/1/2018
Device manufacturers count on their supply chain partners for answers. What can be adjusted, how can we add value, and what methods can be used to streamline manufacturing processes, reduce SKUs, and improve part quality? One way is by moving from single-component molding to two-component molding.
Aluminum Alloy, Extruded Profiles (7349-T76511) 8.1Zn - 1.7Cu - 2.2Mg - 0.16Zr Solution Heat Treated, Stress-Relieved, and OveragedAMS4332A (Current)4/28/2018
This specification covers an aluminum alloy procured in the form of extruded profiles (shapes) with cross-sections up to 0.750 inch (19.05 mm) (see 8.5).
AMS D Nonferrous Alloys Committee
Fracture Characteristic Prediction of High-Strength Aluminum Alloy Extrusion using Cockcroft-Latham Ductile Fracture Criteria2018-01-01094/3/2018
Demands are increasing for the reduction of vehicle weight to enhance automobile fuel efficiency and driving performance, with the use of aluminum alloys expected to help. High-strength aluminum alloys (6xxx series, 7xxx series) are called for to enhance crash safety performance, and the prediction of material fracture is a key factor in the application of these alloys. This research presents a FEM model that can predict both tensile fracture and bending fracture when large deformations occur in the extrusion direction of high-strength aluminum alloy extrusion. The fracture characteristics of high-strength aluminum alloy extrusion were obtained by tensile and bending tests, and the factors governing ductile performance were clarified. Fracture was defined in the FEM model using the Cockcroft-Latham ductile fracture model. In addition, the surface crystal grain of aluminum extrusion becomes coarse as a result of the extrusion process, and the hardness distribution also exhibits a soft
Sugimoto, Nao, Takaki, Naoki, Takada, Kenji
Dimensional Variation in Long Runout Length Direct Extruded 6000 Series Aluminum Alloy2018-01-01044/3/2018
In a drive to reduce overall vehicle weight, automotive manufacturers continue to look to aluminum alloys as a solution to provide complex lightweight structures. Precipitation hardened 6000 series aluminum alloys offer a mature commercially viable solution which may be produced using several different forming methods including the extrusion process. In some cases, aluminum products may be produced at a temper suitable for forming and later precipitation hardened to a temper with mechanical properties that meet structural requirements. Direct extrusion press capabilities continue to expand. In an effort to improve productivity, the runout lengths for presses have increased in an effort to reduce dead cycle time inherent to billet heating and loading. Long runouts, however, result in larger differences in pressure applied during extrusion. This pressure variation, confounded with differences in quenching and stretching, causes variation in the extruded product. The purpose of this study
Vinarcik, Edward John, Talbert, Gregory
System Measures Nanoliter Flow RatesTBMG-289594/1/2018
A microflow measurement system can track the movement of extremely tiny amounts of liquids — as small as nanoliters. The invention is designed to fill a need in the rapidly expanding field of microfluidics, in which precisely measuring tiny flow rates is critical. For example, some medical drug-delivery pumps dispense as little as tens of nL per minute into the bloodstream.
Microextrusion Tubing Advances Help Push Medical Device BoundariesTBMG-285203/1/2018
Over the past five years, technological advances have enabled product applications for microextrusion to penetrate into the medical OEM arena. Simply speaking, micro now really means micro. Years ago, when an OEM was asking for micro tubing, they typically were looking for ranges between 0.060 and 0.100 in. OD with 2-4 lumens. Now micro range dimensions are down to 0.024 in. OD with up to 6 lumens, including an ID range as low as 0.003 in.
3D Printed Microfibers Could Provide Structure for Artificially Grown Body PartTBMG-282561/15/2018
Much as a frame provides structural support for a house and the chassis provides strength and shape for a car, a team of engineers believe they have a way to create the structural framework for growing living tissue using an off-the-shelf 3-D printer.
Additive Manufacturing Facility for Utilization Primarily in Microgravity EnvironmentsTBMG-281521/1/2018
The purpose of this innovation is to create the ability to manufacture off Earth, primarily in a microgravity environment. This additive manufacturing facility (AMF) will have the capability to build tools, parts, experimental hardware, and upgrade hardware while primarily being utilized in microgravity environments.
Extrusion Method Improves Structural Properties of MagnesiumTBMG-281721/1/2018
Magnesium is 75 percent lighter than steel, 33 percent lighter than aluminum, and is the fourth most common element on Earth behind iron, silicon, and oxygen. But despite its light weight and natural abundance, automakers have been halted in their attempts to incorporate magnesium alloys into structural car parts. To provide the necessary strength has required the addition of costly rare elements such as dysprosium, praseodymium, and ytterbium.
Vote for Medical Design Briefs Annual Readers' Choice AwardsTBMG-2807012/7/2017
Each month, the editors of Medical Design Briefs choose a Product of the Month that has exceptional technical merit and practical value for MDB’s design engineering readers.
Stronger Silk Offers Biomedical ApplicationsTBMG-2790711/15/2017
Engineers have found they can make a material that is more than twice as stiff as its natural counterpart and can be shaped into complex structures such as meshes and lattices.
Aluminum Alloy, Extruded Profiles (2024-T432) 4.4Cu - 1.5Mg - 0.6Mn Annealed, Stretch Formed, Solution Heat Treated and Stress Relieved by StretchingAMS4402 (Historical)11/14/2017
This specification covers an aluminum alloy in the form of extruded profiles (shapes).
AMS D Nonferrous Alloys Committee
Rubber, Fluorosilicone Elastomer, Oil-and-Fuel-Resistant, Sheets, Strips, Molded Parts, and Extruded ShapesAMSR25988A (Historical)8/4/2017
This specification covers oil-and-fuel-resistant fluorosilicone elastomer rubber sheets, strips, molded parts, and extruded shapes for aeronautical and aerospace applications.
AMS CE Elastomers Committee
Researchers 'Stretch' Limits of ElastomersTBMG-264182/21/2017
Researchers from the Singapore University of Technology and Design's Digital Manufacturing and Design Centre have developed UV-curable elastomers that can be stretched by up to 1100%. The 3D-printing process supports the fabrication of soft actuators and robots, flexible electronics, and acoustic metamaterials.
Avoiding Pitfalls in Development of Advanced Custom ExtrusionsTBMG-254039/1/2016
The custom medical extrusion industry is growing in all directions. The push to be minimally invasive is pushing devices to be smaller and smaller. Cutting-edge raw materials are constantly being reformulated to enhance or create new mechanical and biologic characteristics in the function of the part. In short, the matrix of technologies integrated into today’s catheters and devices has become increasingly complex, and subsequently interpreting quality is becoming more challenging for all parties either producing the component parts or using the parts.
Rope, Aramid Fiber, Jacketed Parallel Strand, Extruded JacketAMS3813/2B (Current)6/20/2016
This specification covers parallel-strand ropes formed from impregnated aramid fibers.
AMS P Polymeric Materials Committee
Meshing Considerations for Automotive Shape Design Optimization2016-01-13894/5/2016
High quality mesh generation technology coupled with a robust shape deformation technique enables large design space exploration for optimization without the need to remesh the geometry. To demonstrate this, we present a collection of best practices for cleaning complex analytic CAD data that together with a robust grid generation algorithm enable the automatic generation of high quality boundary layer resolved grids that retain their quality when morphed during the optimization process. The case study for this work is the DrivAer model developed by the Institute of Aerodynamics and Fluid Mechanics at the Technische Universität München. The first step in the proposed automated optimization framework is to use a technique called Solid Meshing to heal faults in the provided geometry and recover its original engineering intent. The aforementioned technique coupled with Pointwise’s anisotropic tetrahedral extrusion algorithm (T-Rex), enables automated, high quality volumetric grid
Carrigan, Travis, Landon, Mark, Pita, Claudio
Intelligent Tubing for Bioresorbable ScaffoldsTBMG-241443/1/2016
Bioresorbable stent scaffolds are balloon-expandable and have been used to replace metallic stents to treat the narrowing of arteries and airway passages. Like traditional metallic scaffolds, bioresorbable scaffolds provide artery and/or airway support and act as a delivery system for the controlled release of an anti-inflammatory drug to prevent narrowing of the vessel lumen. Unlike metallic scaffolds that are permanent, bioresorbable scaffolds degrade over time and are completely absorbed and eliminated from the body after they are implanted, and therefore eliminate the need for additional surgical procedures. Bioresorbable scaffolds are used in coronary, peripheral, neural, and nasal applications. Each application has different scaffold sizes (OD and wall thicknesses), vessel support requirements, and degradation times.
Type 5 Virgin Polytetrafluoroethylene (PTFE) Moldings or Extrusions with PigmentAMS3678/5B (Current)2/29/2016
This specification covers a polytetrafluoroethylene (PTFE) resin filled with inorganic pigment in the form of extruded or molded rods or tubes which are sintered after molding or, in the case of extrusions, sintered during the extrusion process.
AMS P Polymeric Materials Committee
Type 3 15% Glass, 5% Molybdenum Disulfide Filled Virgin Polytetrafluoroethylene (PTFE) Moldings or ExtrusionsAMS3678/3B (Current)2/29/2016
This specification covers a polytetrafluoroethylene (PTFE) resin filled with 15% glass fiber and 5% molybdenum disulfide in the form of extruded or molded rods or tubes which are sintered after molding or, in the case of extrusions, sintered during the extrusion process.
AMS P Polymeric Materials Committee
Type 4 25% Glass Filled Virgin Polytetrafluoroethylene (PTFE) Moldings or ExtrusionsAMS3678/4B (Current)2/29/2016
This specification covers a polytetrafluoroethylene (PTFE) resin filled with 25% glass fiber in the form of extruded or molded rods or tubes which are sintered after molding or, in the case of extrusions, sintered during the extrusion process.
AMS P Polymeric Materials Committee
Type 15 15% Aromatic Polymer Filled Virgin Polytetrafluoroethylene (PTFE) Moldings or ExtrusionsAMS3678/15A (Current)2/29/2016
This specification covers a polytetrafluoroethylene (PTFE) resin filled with 15% aromatic polymer in the form of extruded or molded rods or tubes which are sintered after molding or, in the case of extrusions, sintered during the extrusion process.
AMS P Polymeric Materials Committee
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