What is hybrid extrusion?
Advantages of combining plastic extrusion with the mechanical strengths of inserts
Hybrid extrusion is an innovative manufacturing process that combines the advantages of traditional plastic extrusion with the mechanical strength of metallic inserts. During extrusion, thermoplastic materials are directly reinforced with metal elements such as wires or cords.
The key: reinforcement takes place inline, during the continuous process, eliminating the need for additional production steps. The result is a composite profile that unites the best of both material worlds – lightweight and flexible like plastic, but stable and durable like metal.
Why hybrid extrusion?
Plastics offer design freedom, low weight, and excellent processability. However, when it comes to high tensile or bending strength requirements, they quickly reach their limits.
This is where hybrid extrusion comes into play: by integrating metallic reinforcements, the mechanical performance of the end product can be significantly improved.
The smart part: reinforcement is applied exactly where it is needed. This not only makes components more robust but also more material-efficient – a crucial factor in modern lightweight engineering.
Advantages
- Lightweight potential: Reduced weight with the same or even higher stability
- Material efficiency: Reinforcement only in critical areas – less resource consumption
- Process integration: No additional production steps required
- Reproducibility: High precision and consistent quality at large-scale throughput
- Cost efficiency: Technical performance boost combined with economic attractiveness
What are possible applications of hybrid extrusion?
The range of applications is wide – wherever components need to be lightweight yet highly durable:
- Automotive engineering: Structural parts, crash absorbers, guiding systems
- Window and façade systems: Slim profiles with enhanced stability
- Sealing systems: Flexible but reinforced geometries for long-lasting use
- General lightweight design: Components requiring the balance between weight reduction and strength
Conclusion
Hybrid extrusion opens new possibilities for intelligently combining materials to create components with optimized properties. For designers and engineers, this means: greater design freedom, higher performance, and a production technology that is both technically and economically attractive.
Given the increasing demand for lighter, more efficient, and sustainable products, hybrid extrusion is a process that will continue to gain importance in the future.