What is the fundamental definition of extrusion as a manufacturing process?

Extrusion is a manufacturing process used to create objects with a fixed cross-sectional profile by pushing material through a die that has the desired cross-sectional shape. This process is particularly effective for creating complex shapes and working with materials that might otherwise be brittle.

What are the primary advantages of extrusion compared to other manufacturing methods?

The two main advantages of extrusion are its ability to create very complex cross-sectional profiles and its capacity to work with materials that are brittle, as the material only encounters compressive and shear stresses. Additionally, it results in an excellent surface finish and offers significant design freedom.

How does extrusion differ from the process of drawing?

Drawing is a similar process that uses the material's tensile strength to pull it through a die. However, drawing is limited to simpler shapes and often requires multiple stages because it cannot achieve as much change in a single step as extrusion can. Drawing is the primary method for producing wire.

What types of materials can be processed using extrusion?

Extrusion can be used with a wide variety of materials, including metals, polymers, ceramics, concrete, modeling clay, and even foodstuffs. The process can be performed with materials that are either hot or cold.

What are the products of the extrusion process generally referred to as?

The objects or materials produced through the extrusion process are generally called extrudates.

Who patented the first extrusion process, and what was its initial application?

Joseph Bramah patented the first extrusion process in 1797. His initial method was designed for creating pipe from soft metals by preheating the metal and forcing it through a die using a hand-driven plunger.

How did the extrusion process evolve in the early 19th century?

In 1820, Thomas Burr implemented Joseph Bramah's extrusion process for lead pipe, utilizing a hydraulic press, which Bramah had also invented. At this time, the process was commonly referred to as "squirting."

What is the extrusion ratio, and why is it considered a key advantage?

The extrusion ratio is defined as the ratio of the starting cross-sectional area of the material to the cross-sectional area of the final extrusion. A significant advantage of the extrusion process is that this ratio can be very large while still yielding quality parts.

What is hot extrusion, and why is it performed above the material's recrystallization temperature?

Hot extrusion is a hot working process conducted at temperatures above the material's recrystallization temperature. This is done to prevent the material from work hardening, making it easier to push through the die, and to improve its ductility.

What are the typical capacities of hydraulic presses used for hot extrusion, and what pressures do they operate under?

Hydraulic presses used for hot extrusion typically range from 230 to 11,000 metric tons (250 to 12,130 short tons) and operate under pressures from 30 to 700 MPa (4,400 to 101,500 psi).

What types of lubricants are used in hot extrusion, and why are they necessary?

Lubrication is required in hot extrusion due to the high pressures involved. For lower temperature extrusions, oil or graphite is used, while glass powder is employed for higher temperature extrusions. Lubrication reduces friction and wear on the die and tooling.

What is the primary disadvantage of the hot extrusion process?

The main disadvantage of hot extrusion is its high cost, primarily associated with the machinery required and its ongoing maintenance.

What are the hot extrusion temperatures for specific metals like Aluminium, Copper, and Steel?

The hot extrusion temperatures vary by metal: Aluminium is extruded between 350–500 °C (650–900 °F), Copper between 600–1,100 °C (1,200–2,000 °F), and Steel between 1,200–1,300 °C (2,200–2,400 °F). Other metals like Magnesium, Titanium, and Nickel also have specific temperature ranges.

When does roll forming become more economical than extrusion for producing steel parts?

Roll forming becomes more economical than extrusion for steel production when the quantity required exceeds approximately 20,000 kg (50,000 lb).

What is cold extrusion, and what are its advantages over hot extrusion?

Cold extrusion is performed at or near room temperature. Its advantages over hot extrusion include the absence of oxidation, increased material strength due to cold working, tighter tolerances, a better surface finish, and faster extrusion speeds, especially for materials prone to hot shortness.

What are some common examples of products manufactured using cold extrusion?

Products commonly made through cold extrusion include collapsible tubes, fire extinguisher cases, shock absorber cylinders, and gear blanks.

What is warm extrusion, and what temperature range does it typically operate within?

Warm extrusion is performed at temperatures above room temperature but below the material's recrystallization temperature. The temperature range for warm extrusion is generally between 800 to 1,800 °F (424 to 975 °C). This process aims to balance the required forces, ductility, and final extrusion properties.

When and where was friction extrusion invented, and what was its initial purpose?

Friction extrusion was invented at the Welding Institute in the UK and patented in 1991. It was initially developed primarily as a method for producing homogeneous microstructures and particle distributions in metal matrix composite materials.

How does friction extrusion differ from conventional extrusion?

Friction extrusion differs from conventional extrusion because the material charge rotates relative to the extrusion die. This relative rotary motion generates significant shear stresses, causing plastic deformation and internal heating, which can eliminate the need for preheating the material.

What is micro-extrusion, and what are the challenges associated with its machinery?

Micro-extrusion is a microforming extrusion process conducted at the submillimeter scale, where the resulting product's cross-section can fit through a 1 mm square. A major challenge in creating microextrusion machines is the precise manufacture of the small die and ram components, requiring highly accurate manufacturing processes.

What are the four major characteristics that differentiate extrusion equipment?

Extrusion equipment varies based on four main characteristics: the movement of the extrusion relative to the ram (direct vs. indirect), the position of the press (vertical or horizontal), the type of drive (hydraulic or mechanical), and the type of load applied (conventional or hydrostatic).

What is the difference between direct and indirect extrusion in terms of ram and die movement?

In direct extrusion (forward extrusion), the billet is placed in a container, and a ram pushes it through a stationary die. In indirect extrusion (backward extrusion), the billet and container move together while the die remains stationary, with a stem holding the die in place.

What are the advantages of indirect extrusion over direct extrusion?

Indirect extrusion offers several advantages, including a reduction in friction (25-30%), allowing for larger billets and higher speeds; less tendency for extrusions to crack due to reduced friction-induced heat; longer life for the container liner due to less wear; and more uniform billet usage, reducing extrusion defects.

What are the disadvantages of indirect extrusion?

The disadvantages of indirect extrusion include the fact that impurities and surface defects on the billet directly affect the extrusion's surface finish, potentially ruining pieces where aesthetics are important or anodizing is required. Additionally, the process is less versatile as the cross-sectional area is limited by the maximum size of the stem.

How does hydrostatic extrusion work, and what are its primary advantages?

In hydrostatic extrusion, the billet is fully enclosed by a pressurized liquid, except where it meets the die. This process eliminates friction between the container and the billet, leading to reduced force requirements, faster speeds, higher reduction ratios, and lower billet temperatures. It also often increases material ductility.

What are the disadvantages of hydrostatic extrusion?

Disadvantages of hydrostatic extrusion include the need to taper one end of the billet to create a seal, the requirement for the entire billet to be machined to remove surface defects, the difficulty in containing the fluid under high pressures, and the necessity of leaving a billet remnant or plug to prevent sudden fluid release.

What are the two types of hydraulic presses used in extrusion, and how do they differ?

The two types of hydraulic presses are direct-drive oil presses and accumulator water drives. Direct-drive oil presses are reliable and robust, delivering constant pressure but are slower (50-200 mm/s). Accumulator water drives are more expensive and larger but much faster (up to 380 mm/s), making them suitable for extruding steel or materials requiring very high temperatures for safety.

What medium and pressure are typically used in hydrostatic extrusion presses?

Hydrostatic extrusion presses commonly use castor oil at pressures up to 1,400 MPa (200 ksi). Castor oil is chosen for its good lubricity and high-pressure properties.

How does the design of an extrusion profile influence its extrudability?

The design of an extrusion profile significantly impacts its extrudability. Factors like the complexity of the shape, the presence of sharp corners, and the relative dimensions of different sections (e.g., leg length to thickness ratio) all affect how readily the material can flow through the die.

What is a 'circumscribing circle' in die design, and how does it relate to press capacity?

A circumscribing circle is the smallest circle that can fit around the cross-section of an extruded profile. Its diameter determines the size of the die required and, consequently, whether the part can be processed in a specific press. Larger presses can handle larger circumscribing circles.

How is the complexity of an extruded profile quantified, and what does it impact?

The complexity of an extruded profile can be quantified by its 'shape factor,' which represents the amount of surface area generated per unit mass of extrusion. This factor influences the cost of the tooling and the overall rate of production.

What are the recommended minimum radii for corners in extrusion design for aluminium and steel?

For aluminium and magnesium, the minimum radius for corners should be 0.4 mm (1/64 in). For steel, corners should have a minimum radius of 0.75 mm (0.030 in), with fillets of 3 mm (0.12 in) recommended.

What are the minimum cross-section and thickness requirements for aluminium and magnesium extrusions?

For aluminium and magnesium, the minimum cross-section is less than 2.5 cm² (0.40 sq. in.), and the minimum thickness is 0.70 mm (0.028 in) for aluminium and 1.00 mm (0.040 in) for magnesium.

Which metal is the most commonly extruded, and what are some of its applications?

Aluminium is the most commonly extruded material. Its applications include profiles for tracks, frames, rails, mullions, and heat sinks.

What are the typical extrusion temperatures for copper and steel?

Copper is typically extruded at temperatures between 600 to 1,100 °C (1,200 to 2,000 °F), while steel requires much higher temperatures, between 1,200 to 1,300 °C (2,200 to 2,400 °F).

What are the typical surface finish requirements for aluminium and steel extrusions?

Magnesium and aluminium alloys usually achieve a surface finish of 0.75 µm (30 µin) RMS or better. Titanium and steel extrusions can achieve a surface finish of 3 micrometers (120 µin) RMS.

Who invented the glass lubrication process for extruding steel, and what is its purpose?

Ugine Séjournet, from France, invented a process in 1950 that uses glass as a lubricant for extruding steel. This process, known as the Ugine-Séjournet or Séjournet process, is also used for other high-melting-point materials and helps insulate the billet from the die.

How is plastic typically prepared for plastics extrusion?

Plastic is typically prepared for extrusion using chips or pellets, which are usually dried to remove moisture before being fed into the machine's hopper.

What is a 'caterpillar haul-off' in plastic extrusion, and why is it important?

A caterpillar haul-off, also known as a 'puller,' is used in plastic extrusion to provide tension on the extruded line. Consistent tension is crucial for the overall quality of the extrudate, preventing variations in cut lengths or product distortion.

How is extrusion used in 3D printing?

In 3D printing, particularly in fused filament deposition, extrusion is the process where an extruder, often a geared motor, pushes plastic filament through a nozzle to build objects layer by layer.

What is rubber extrusion, and what are the main components of a rubber extruder?

Rubber extrusion is a method for creating rubber items by forcing unhardened natural or synthetic rubber through a shaped mold. A rubber extruder typically consists of a screw that moves the rubber and adds materials, and a mold that shapes the softened rubber.

What types of ceramic materials are formed via extrusion, and what are some common products?

Ceramic materials like terracotta are formed via extrusion to produce pipes. Additionally, many modern bricks are manufactured using a brick extrusion process.

When did extrusion become a significant application in food processing?

With the advent of industrial manufacturing, extrusion found significant application in food processing for instant foods and snacks, complementing its established uses in plastics and metal fabrication.

What are some examples of food products commonly manufactured by extrusion?

Products commonly manufactured by extrusion include certain pastas, many breakfast cereals, cookie dough, some french fries, certain baby foods, dry or semi-moist pet food, and ready-to-eat snacks. It is also used for modified starch and pelletizing animal feed.

How does extrusion cooking contribute to the shelf life and variety of food products?

Extrusion cooking typically results in products with low moisture content, which significantly increases their shelf life. It also provides consumers with variety and convenience in their food choices.

What are the main independent parameters that influence the extrusion cooking process?

The key independent parameters that influence extrusion cooking include the feed rate, the particle size of the raw material, the barrel temperature, the screw speed, and the moisture content of the ingredients.

How is extrusion utilized in pharmaceutical applications for drug delivery?

In pharmaceuticals, extrusion through nano-porous filters is used to create suspensions of lipid vesicles like liposomes with a narrow size distribution, for example, in doxorubicin delivery systems. Hot melt extrusion is also used to disperse poorly soluble drugs in polymer carriers, enhancing their dissolution rates and bioavailability.

What is the process for producing fuel briquettes from biomass waste using extrusion?

The extrusion production technology for fuel briquettes involves processing waste materials like straw, sunflower husks, buckwheat, or sawdust under high pressure and heat (160 to 350 °C). The natural lignin in the plant waste melts during compression, acting as a binder and solidifying the briquettes.

How are synthetic fibers in textiles manufactured using extrusion?

The majority of synthetic materials used in textiles are manufactured through extrusion. Fiber-forming substances are passed through a spinneret, which is a device with fine holes, to form the synthetic filaments that make up the fibers.

What is the role of a spinneret in textile fiber production?

A spinneret is a crucial component in the extrusion process for textiles. It is a device with multiple fine holes through which molten or dissolved fiber-forming materials are passed to create continuous filaments, which are then processed into fibers.

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What is Extrusion?

Core Process

Extrusion is a fundamental manufacturing process used to create objects of a fixed cross-sectional profile by pushing material through a die of the desired shape. Its primary advantages lie in its ability to produce intricate cross-sections and to process materials that are inherently brittle, as the material primarily encounters compressive and shear stresses.

Key Advantages

This method offers significant design freedom and typically results in an excellent surface finish. Unlike drawing, which pulls material through a die and is limited in the degree of deformation per step, extrusion can achieve very large extrusion ratios, making it highly efficient for complex shapes and materials that would otherwise be difficult to form.

Continuous vs. Semi-Continuous

Extrusion can be performed as a continuous process, theoretically yielding indefinitely long products, or as a semi-continuous process, producing multiple discrete pieces. The material can be processed either hot or cold, depending on its properties and the desired outcome.

Historical Development

Early Innovations

The origins of extrusion can be traced to 1797 when Joseph Bramah patented a method for extruding soft metals. His process involved preheating the metal and forcing it through a die using a hand-driven plunger. By 1820, Thomas Burr adapted this for lead pipe, utilizing a hydraulic press—also a Bramah invention—and referring to the process as "squirting."

Expansion and Refinement

The technique continued to evolve. In 1894, Alexander Dick expanded the extrusion process to include copper and brass alloys. These early developments laid the groundwork for the widespread application of extrusion across various industries, enabling the creation of more complex and durable metal components.

Extrusion Methodologies

Hot Extrusion

This process is conducted above the material's recrystallization temperature, preventing work hardening and facilitating material flow. It typically employs large hydraulic presses (250 to 12,130 short tons) operating at pressures from 4,400 to 101,500 psi. Lubrication, such as oil or graphite for lower temperatures and glass powder for higher temperatures, is essential. The primary drawback is the significant machinery cost and upkeep.

Material	Temperature [°C (°F)]
Magnesium	350–450 (650–850)
Aluminium	350–500 (650–900)
Copper	600–1,100 (1,200–2,000)
Steel	1,200–1,300 (2,200–2,400)
Titanium	700–1,200 (1,300–2,100)
Nickel	1,000–1,200 (1,900–2,200)
Refractory alloys	up to 2,000 (4,000)

Cold Extrusion

Executed at or near room temperature, cold extrusion offers several advantages: it avoids oxidation, enhances material strength through cold working, achieves tighter tolerances, and provides a superior surface finish. It is also faster for materials prone to hot shortness. Common materials include lead, tin, aluminum, copper, titanium, and steel.

Warm Extrusion

This method operates at temperatures above ambient but below the recrystallization point, typically ranging from 800 to 1,800 °F (424 to 975 °C). Warm extrusion is employed to achieve an optimal balance between the required forces, material ductility, and the final properties of the extruded product.

Friction Extrusion

A distinct process where the material charge rotates relative to the extrusion die. This relative motion generates significant shear stresses and plastic deformation, leading to internal heating that often eliminates the need for preheating. It's particularly effective for consolidating powders and creating homogeneous microstructures in composite materials.

Micro-extrusion

Performed in the sub-millimeter range, micro-extrusion is a microforming process. It involves pushing metal through a die orifice to create products with cross-sections fitting within a 1 mm square. Key challenges include the precise manufacturing of miniature dies and rams, and resolving issues related to deformation loads, defects, and size-dependent material properties.

Machinery and Components

Press Configurations

Extrusion equipment varies significantly, characterized by four main aspects: the relative movement of the extrusion and ram (direct vs. indirect), press orientation (vertical vs. horizontal), drive type (hydraulic vs. mechanical), and load application (conventional vs. hydrostatic). Most modern presses are hydraulically driven.

Drive Systems

Hydraulic presses are common, with direct-drive oil presses offering reliability and constant pressure but slower speeds (2-8 ips). Accumulator water drives are faster (up to 15 ips) and used for materials like steel or those requiring very high temperatures for safety, though they are more expensive and larger.

Forming Internal Cavities

Creating hollow sections involves methods like using a hollow billet with a fixed or floating mandrel, or piercing a solid billet before extrusion. Alternatively, specialized dies like spider, porthole, or bridge dies incorporate the mandrel directly into the die, allowing material to flow around supports and fuse, forming the desired shape.

Die Design Principles

Profile and Size Constraints

The complexity and size of an extruded profile are dictated by the "circumscribing circle"—the smallest circle that can encompass the cross-section. This diameter influences the die size and, consequently, the press capacity required. For instance, aluminum can accommodate larger circumscribing circles than steel or titanium.

Design for Manufacturability

Ease of extrusion is heavily influenced by design. Guidelines suggest that "legs" of a profile should not exceed ten times their thickness. Sharp corners should be rounded (minimum radius of 0.4 mm for aluminum/magnesium, 0.75 mm for steel). Asymmetrical sections should have adjacent parts of similar size to ensure uniform material flow.

Material	Minimum Cross-Section [cm² (sq. in.)]	Minimum Thickness [mm (in.)]
Carbon steels	2.5 (0.40)	3.00 (0.120)
Stainless steel	3.0–4.5 (0.45–0.70)	3.00–4.75 (0.120–0.187)
Titanium	3.0 (0.50)	3.80 (0.150)
Aluminium	< 2.5 (0.40)	0.70 (0.028)
Magnesium	< 2.5 (0.40)	1.00 (0.040)

Shape Factor

The "shape factor" quantifies the surface area generated per unit mass of extrusion. This metric is crucial for estimating tooling costs and production rates, as more complex shapes with higher surface area-to-volume ratios can present greater manufacturing challenges.

Materials and Their Extrusion

Metals

Aluminium is the most frequently extruded metal, suitable for both hot and cold processes, yielding profiles for frames, heat sinks, and structural components. Brass is used for corrosion-resistant rods and fittings. Copper, requiring higher pressures, forms pipes and electrodes. Lead and tin are extruded into pipes and sheathing. Magnesium, similar to aluminum, is used in aerospace. Steel and titanium, requiring high temperatures, are extruded for structural parts and engine components.

Plastics

Plastic extrusion is a ubiquitous process, starting with dried pellets fed into a heated barrel with a screw. The molten polymer is forced through a die, cooled, and pulled by a haul-off mechanism. This method is fundamental for producing pipes, films, profiles, and is also employed in 3D printing filament extrusion.

Rubber

Uncured rubber is heated and softened within an extruder, then pushed through a shaped mold. The resulting form is subsequently vulcanized to harden it. This technique is cost-effective for producing long, consistent rubber items like seals and hoses, benefiting from inexpensive dies.

Ceramics

Ceramic materials can also be extruded, notably in the production of pipes and bricks. The process shapes the ceramic slurry into the desired form before firing, making it a key method in construction and infrastructure material manufacturing.

Diverse Applications

Food Processing

Extrusion is a cornerstone of modern food manufacturing, used for products like pasta, breakfast cereals, snacks, and pet food. It facilitates sophisticated processing functions including mixing, heating, shaping, and sterilization, often utilizing high-temperature extrusion for ready-to-eat items and cold extrusion for pasta.

Pharmaceutical Delivery

In pharmaceuticals, extrusion is employed for drug delivery systems, such as creating liposomes and transfersomes with controlled particle sizes. Hot melt extrusion is also vital for improving the solubility and bioavailability of poorly soluble drugs by dispersing them within polymer carriers.

Biomass Briquettes

Extrusion technology converts biomass waste (like straw or sawdust) into fuel briquettes. High pressure and heat cause the natural lignin within the plant material to melt, acting as a binder without external additives, creating dense, solid fuel sources.

Textiles

The production of most synthetic fibers relies on extrusion. Molten materials are forced through a spinneret, a die with numerous fine holes, to form continuous filaments that are then processed into textiles.

Advanced Extrusion Techniques

Direct Extrusion

The most common method, where a ram pushes a billet through a stationary die. A dummy block separates the ram from the billet. The primary disadvantage is friction between the billet and container, requiring higher forces, especially at the end of the extrusion cycle, leading to unused "butt ends."

Indirect Extrusion

In this process, the die moves towards a stationary ram, and the billet moves with the container. This eliminates friction between the billet and container, reducing force requirements, increasing speed, and improving surface finish. However, it is limited by the stem's column strength and is sensitive to billet surface defects.

Hydrostatic Extrusion

The billet is fully enclosed in a pressurized liquid medium, except where it contacts the die. This significantly reduces friction, allowing for faster speeds, higher reduction ratios, and lower extrusion temperatures. Challenges include containing the high-pressure fluid and preparing the billet end to form a seal.

Lubrication and Surface Treatment

Specialized lubrication techniques are critical. The Sejournet process uses glass as a lubricant for high-temperature extrusions like steel, insulating the billet from the die. Phosphate coatings combined with glass lubrication enable cold extrusion of steel. These methods enhance material flow and protect tooling.

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References

Backus et al. 1998, pp. 13-11â12, Hot extrusion

âForming metallic composite materials by urging base materials together under shearâ US patent #5262123 A, Inventors: W. Thomas, E. Nicholas, and S. Jones, Original Assignee: The Welding Institute.

Backus et al. 1998, pp. 13â21, Hot extrusion: Tooling

Backus et al. 1998, p. 13-13, Hot extrusion: Methods of extruding: Direct extrusion

James Bralla (1999) 'CHAPTER 3.1 METAL EXTRUSIONS', in (ed.) Design for Manufacturability Handbook. : McGraw Hill Professional, pp. 3.3-3.14.

Brick manufacturing process

A full list of references for this article are available at the Extrusion Wikipedia page

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This is not professional advice. The information provided on this website is not a substitute for professional engineering, manufacturing, or material science consultation. Always refer to official documentation and consult with qualified professionals for specific project needs. Never disregard professional advice because of something you have read on this website.

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Extrusion: Forging Form Through Force

💡 Dive in with Flashcard Learning! 💡

What is Extrusion? ℹ️

🗜️ Core Process

✨ Key Advantages

🔄 Continuous vs. Semi-Continuous

Historical Development ⏳

📜 Early Innovations

🚀 Expansion and Refinement

Extrusion Methodologies 🌡️

🔥 Hot Extrusion

❄️ Cold Extrusion

🌤️ Warm Extrusion

⚡ Friction Extrusion

🔬 Micro-extrusion

Machinery and Components 🏭

⚙️ Press Configurations

🗜️ Drive Systems

🔗 Forming Internal Cavities

Die Design Principles 📐

📏 Profile and Size Constraints

📐 Design for Manufacturability

💡 Shape Factor

Materials and Their Extrusion 🧱

🔩 Metals

🧪 Plastics

💧 Rubber

🧱 Ceramics

Diverse Applications 🍽️

🍽️ Food Processing

💊 Pharmaceutical Delivery

🌱 Biomass Briquettes

🧵 Textiles

Advanced Extrusion Techniques 🔄

➡️ Direct Extrusion

⬅️ Indirect Extrusion

💧 Hydrostatic Extrusion

💡 Lubrication and Surface Treatment

Teacher's Corner 🧑‍🏫

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References

📜 References

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Disclaimer ⚠️

📜 Important Notice

Dive in with Flashcard Learning!

What is Extrusion?

Core Process

Key Advantages

Continuous vs. Semi-Continuous

Historical Development

Early Innovations

Expansion and Refinement

Extrusion Methodologies

Hot Extrusion

Cold Extrusion

Warm Extrusion

Friction Extrusion

Micro-extrusion

Machinery and Components

Press Configurations

Drive Systems

Forming Internal Cavities

Die Design Principles

Profile and Size Constraints

Design for Manufacturability

Shape Factor

Materials and Their Extrusion

Metals

Plastics

Rubber

Ceramics

Diverse Applications

Food Processing

Pharmaceutical Delivery

Biomass Briquettes

Textiles

Advanced Extrusion Techniques

Direct Extrusion

Indirect Extrusion

Hydrostatic Extrusion

Lubrication and Surface Treatment

Teacher's Corner

True or False?

Test Your Knowledge!

Gamer's Corner

Discover other topics to study!

References

Feedback & Support

Disclaimer

Important Notice