Which factors determine the tooling price?
An extrusion tool is, at its core, a precisely cut contour in hardened steel plus the matching calibration. Seven factors drive the effort:
- Profile size and contour length
The larger the cross-section and the longer the contour line, the more EDM and machining work is in the tool.
- Geometric complexity
Hollow chambers need mandrels and cores; filigree webs and tight radii increase manufacturing and tuning effort considerably.
- Calibration
The number of calibration stages and the length of the calibration section grow with precision demands and hollow-chamber content, an underestimated cost driver.
- Co- or tri-extrusion
Every additional component needs its own melt channels in the tool plus tuning of all components to the same exit speed.
- Material
Abrasive or corrosive melts, such as filled grades or PVC, demand hardened or coated tool components.
- Tolerances and surfaces
Tight functional dimensions and high surface requirements increase finishing and inspection effort.
- Adjustment loops during sampling
Every tuning round costs machine time. Good upfront design reduces the loops; it cannot fully replace them.
From order to sample: how does it work?
The industry-standard path has six stations: feasibility check of your geometry, an agreed manufacturing drawing, tool build (at Heller with CNC wire EDM in-house), test extrusion with adjustment, approval samples for your inspection and finally the production drawing as the reference for all series. Publicly quoted industry figures for development and build range around 4–8 weeks depending on complexity.
The point that decides quality: no serious extruder sells you a tool without sampling. Die swell and shrinkage can only be calculated to a limited extent; fine-tuning on the real tool is an integral part of the process. At Heller you receive samples after tool completion, and series production starts only after your approval. How our toolmaking works
Does it pay off for my small series?
More often than expected. The industry rule of thumb: because extrusion tools are considerably cheaper than injection moulds, they amortise even at small and medium quantities. On top of that, a profile often replaces several work steps (cutting, gluing, sealing) or a more expensive machined part. The honest answer comes from a simple calculation of tooling price, price per metre and your demand, and we make exactly that calculation transparent with you. Heller explicitly welcomes very small quantities.
What should you provide for a solid quotation?
- Drawing, sketch or sample: ideally as PDF, DXF or STEP; a photographed hand sample works for the first assessment too.
- Installation situation and function: what must the profile do: seal, clamp, guide, protect?
- Material preference: if available; otherwise we advise based on the requirements. The material comparison helps.
- Demand frame: a rough annual quantity or batch size is enough for the economics assessment.
- Critical dimensions and tolerances: mark what really matters.
Everything at hand? Then straight to the profile enquiry with file upload: you will receive a first technical assessment from our sales team.
