How Copper & Metal Extrusions Are Made
Understanding how copper and other metals are formed into consistent bars and profiles through controlled extrusion processes.
How Are Extrusions Made?
Metal extrusion creates long, consistent sections by forcing material through a shaped die under pressure. The die determines the cross-section of the finished extrusion, so the same process yields plain bars and rods as well as more specialised profiles.
Copper suits extrusion particularly well. It can be formed while keeping the electrical conductivity and corrosion resistance that make it valuable across electrical, engineering and industrial applications.
At ILF Products, copper extrusion forms part of a wider UK copper manufacturing capability. Specifically, it feeds copper bar production alongside cutting, punching, bending, CNC machining and finishing.
What Is the Extrusion Process?
Every extrusion starts with a solid piece of metal known as a billet. The billet is prepared and, where required, heated before it enters an extrusion press.
Next, pressure forces the material through a precision die. As the metal passes through, it takes on the required cross-sectional shape and emerges as a continuous length.
Finally, the extrusion can be cooled, straightened and cut before any further processing demanded by the finished specification.
Discuss Your Extrusion Requirements with an Expert Today
Common Extrusion Methods
Several extrusion methods exist, and the right choice depends on the material, the profile, production requirements and the characteristics needed from the finished product.
Indirect Extrusion
In indirect, or backward, extrusion, the die moves towards a stationary billet instead of the billet being pushed through a fixed die.
Because this arrangement reduces friction between the billet and the container, it can improve efficiency and surface quality for suitable applications.
Direct Extrusion
Also known as forward extrusion, direct extrusion uses a moving ram to push the billet through a stationary die.
It is one of the most common extrusion methods and is used to make both metal bars and profiles.
Hydrostatic Extrusion
With hydrostatic extrusion, a pressurised fluid surrounds the billet and transfers force to the material.
Because direct friction between the billet and the equipment is reduced, the process allows high levels of deformation and suits more specialised manufacturing requirements.
Hot Extrusion
Copper is commonly heated before extrusion so that it forms more easily. Heating the billet above its recrystallisation temperature lowers its resistance to deformation, and the copper flows through the die more effectively.
Copper Extrusion at ILF
ILF Products has invested in copper extrusion capability at its Cannock manufacturing facility. Copper bar is now produced directly in the UK.
We can produce copper flat bar from 75 mm² to 3,000 mm², with lengths available up to 10 metres. Direct UK production also helps ILF offer shorter lead times, smaller minimum order quantities and greater control over copper supply.
In addition, extruded copper can go straight into our wider manufacturing operation. There we handle cutting, punching, bending, CNC machining, linishing and other specified finishing processes.
Why Use Extrusion?
For engineers who need the same cross-sectional profile over longer lengths, extrusion offers an efficient way of producing consistent metal sections.
Consistent Profiles
A precision die creates a consistent cross-section along the length of the extrusion, supporting repeatability across production quantities.
Flexible Shapes and Sizes
Extrusion can create straightforward bars as well as more complex profiles, depending on the material and production method.
Efficient Production
Once the required tooling and manufacturing process are established, extrusion can provide an efficient production method for repeat quantities.
Reduced Secondary Machining
Producing the material closer to its required finished profile can reduce the amount of metal that subsequently needs to be removed through machining.
Extrusion Methods FAQs
Metal extrusion is a manufacturing process in which metal is forced through a shaped die under pressure to create a continuous bar or profile with a consistent cross-section.
Common methods include direct or forward extrusion, indirect or backward extrusion and hydrostatic extrusion. Different methods manage the movement and friction between the billet, die and extrusion equipment in different ways.
Direct extrusion uses a moving ram to force the billet through a stationary die. It is one of the most widely used methods for producing extruded metal sections.
Indirect extrusion moves the die towards a stationary billet. This reduces friction between the billet and the extrusion container and can provide advantages for suitable profiles and materials.
Heating makes the copper easier to deform and allows it to flow through the extrusion die more effectively while maintaining a controlled material structure.
Yes. ILF operates copper extrusion equipment at its Cannock facility and is currently described both by ILF and Staffordshire Chambers of Commerce as the UK’s only commercial producer of copper bar.