Aluminium & Plastic Extrusion Die Engineering

Practical design calculators for press sizing, feeding ratio, die land length and material selection — built for tooling engineers worldwide.

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Extrusion & Feeding Ratio

Extrusion ratio (EX) and feeding ratio for porthole dies; billet and profile sizing.

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Pressure & Press Tonnage

Estimate required extrusion pressure, all-in force and projected press tonnage. Plastic die head pressure too.

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Die Land Length

Base land length from wall thickness and equalised land for varying profile sections.

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Materials Database

H13 / H11 die steels, extrusion alloys and common plastics with recommended parameters.

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Mandrel & Core Strength

Compression and buckling check for porthole-die mandrels and support pillars.

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Bridge Bending Check

Bending and shear check for porthole-die bridges under uniform or midspan point load.

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Quick workflow

  1. 1. Define profile area and billet; keep extrusion ratio 10 – 50.
  2. 2. For porthole dies keep feeding ratio above 40.
  3. 3. Check press tonnage ≥ required force × safety factor.
  4. 4. Set land length by wall thickness; thicker walls get longer land.
What is extrusion ratio?
Extrusion ratio EX = billet area / profile area. Higher EX gives finer grain and stronger section, but needs more pressure. Keep 10 – 50 for aluminium; porthole dies also need feeding ratio ≥ 40 so the welding chamber fills completely.
All values are estimation guidelines. Final dies must be verified on the press.