Process Details

Services Available

Mechanical Design, CAD Design & 3D Modeling, 3D Rendering & Simulation, Reverse Design & Part Replication, Prototyping Assistance, Manufacturing Process Consulting, Product Development Consulting, Product Support & Manufacturing Documentation

Overview

XtrudeWorks designs custom feed blocks and die transition blocks to optimize polymer flow distribution, layer uniformity, and process flexibility in flat film, sheet, and coextrusion systems. Our designs focus on achieving balanced flow through precision internal geometries, polished flow channels, and thermally stable configurations. Whether integrating into existing die systems or developing from concept, we ensure each block meets process demands for layer control, cleanout accessibility, and thermal uniformity across the profile.

Process Options

• Consultation & Scope Definition → Define film or sheet requirements, material combinations, and extrusion layout needs
• Flow Path Design & Analysis → Design flow geometries and channel splits to optimize layer balance, pressure drop, and transition control with polished flow surfaces and removable inserts or covers to support purging and maintenance
• CAD Modeling & Assembly Configuration → Develop detailed 3D models with alignment features, heater placements, and thermocouple ports as needed for uniform heating and isolation zones to reduce flow instabilities
• Reverse Design of Legacy Blocks → Reconstruct or enhance existing feed block designs for updated die systems or capacity expansion
• Manufacturing Documentation → Deliver drawings, tolerancing, and detailed assembly references for precise fabrication and production teams
• Vendor Coordination & Production Oversight → Assist in sourcing skilled block (CNC) fabricators and validating flow-critical features through inspection
• Installation Oversight & Interface Support → Provide guidance during equipment installation, ensuring correct alignment and interfacing

Design Tools

Autodesk Inventor, AutoCAD, Fusion 360