Cross-Section Structure Optimization: Reducing Production Difficulty from the Source
Simplify Symmetrical Adjustments: Avoid asymmetrical/unbalanced cross-section structures as much as possible. These structures are prone to warping, difficult to control precision, and high mold costs. Prioritize optimizing multi-hole hollow cross-sections to single-hole sections; hollow sections can be converted to semi-hollow sections, and semi-hollow sections to solid sections, gradually simplifying the mold structure and reducing costs.
Large-sized, splicable cross-sections can be divided into multiple smaller sections for splicing, reducing equipment investment in large extrusion presses and large molds, and better ensuring flatness and precision.
Avoid Risky Structures: Avoid structures with large cantilevered sections, small openings, holes smaller than 4mm, and uneven wall thickness. For U-shaped channels with a depth exceeding 100mm, it is recommended to close the opening during the design phase, converting solid molds with insufficient strength into stable flow-dividing molds, and then machining the openings to reduce extrusion deformation.
Detailed Compensation Optimization: For defects in the closing of open profiles, pre-opening error compensation is implemented during the design phase, with the compensation amount determined based on closing experience. Adding reinforcing ribs in the middle of large-span flat profiles improves sagging and wavy deformation caused by self-weight.Leaving allowance at the assembly position for powder coating (approximately 100μm for a single layer, up to 400μm for multiple layers) offsets the impact of coating thickness and mold wear on assembly.
Process Adaptation Optimization: Adapting processing flow to reduce costs and improve efficiency.
Splitting and Secondary Processing: Structures that are difficult to form or too costly with single extrusion are split and combined with secondary processing: small holes with a diameter less than 4mm are directly eliminated from extrusion and replaced with subsequent drilling; ultra-deep grooves are first closed by extrusion and then opened, simplifying the extrusion process.
Complex External, Simplified Internal Design: The external contour can be designed with complex structures according to functional and decorative requirements, while the internal structure is kept as simple as possible, appropriately reducing precision requirements, simplifying mold processing and maintenance, and improving yield.
Specialized Optimizations for Special Profiles: Small/Large Opening Profiles: For openings with a depth ratio exceeding 2: a tear-off design is used. This can be removed after molding and before construction to ensure stability. Eccentric Profiles: Open cavities to prevent mold head swaying; corner profiles are appropriately thickened or have their structure optimized to prevent deformation during transport. Profiles with Similar Shapes: Distinguishing features such as V-lines and raised points are added to avoid production confusion.
