Micro-Extrusion
Micro-extrusion manufacturing is a specialized and precise extrusion process used to create extremely small and intricate parts with tight tolerances. This technology has gained prominence in industries where miniature components are essential. In this web page, we will delve into the different types of micro-extrusion, their advantages and disadvantages, and the industrial applications they serve. Additionally, we will provide a list of materials commonly used in micro-extrusion manufacturing.
Check with one of Canyon’s helpful product engineers for an expert material and manufacturing recommendation.
Common terminology includes: Micro-tubing extrusion, micro-profile extrusion, micro-filament extrusion, precision micro-extrusion, medical micro-extrusion, micro-drip tubing extrusion, micro-rod extrusion, micro-fiber extrusion, micro-precision polymer extrusion.
Custom Micro-Extruded parts available now!
Features of Micro-Extrusion
- • Precision: Micro-extrusion offers exceptional accuracy, critical for micro-scale components.
• Material Efficiency: Minimizes waste, as excess material can often be recycled.
• Complex Geometry: Enables the creation of intricate microstructures with high precision.
• High Production Rates: Suitable for both prototyping and high-volume production.
• Enhanced Material Properties: Certain materials can exhibit improved characteristics after micro-extrusion.
Advantages
Disadvantages
- • Complex Setup: Micro-extrusion may require specialized equipment and tooling.
• Material Limitations: Not all materials are suitable for micro-extrusion.
• Surface Finish: Achieving a smooth surface may necessitate additional processing steps.
Common Applications of Micro-Extrusion
- • Medical: Creating microcatheters, stents, and drug delivery devices.
• Electronics: Fabricating miniature connectors, sensors, and microelectromechanical systems (MEMS).
• Microfluidics: Producing microchannels, microvalves, and lab-on-a-chip devices.
• Optics: Manufacturing micro-optical components, lenses, and optical fibers.
• Biotechnology: Developing microreactors, biochips, and microarrays.
Please consult a Canyon Components Engineer about your specific application and we will use our decades of experience to formulate a solution that fits your need.
Types of Micro-Extrusion
Micro-Extrusion can be performed in a number of ways depending on the composition and intended use of the final product. Some variations available for Micro-Extrusion include the following.
Canyon Components strives to meet all customer service requests. Feel free to contact Canyon Components engineering and let our knowledgeable staff help you design the perfect part for your needs.
Micro-Tubing Extrusion
Specializes in producing tiny tubes used in medical and electronic applications. Its advantage lies in producing highly precise, small-diameter tubes. However, maintaining consistent wall thickness can be challenging, and the process requires specialized equipment.
Micro-Profile Extrusion
Creates miniature profiles for small-scale applications like microfluidics. It offers precision and the ability to create complex shapes. The disadvantage is limited material throughput due to the small size, making the process slower and potentially more expensive.
Micro-Filament Extrusion
Used for producing fine filaments, often for 3D printing or textile applications. This method allows for the creation of extremely thin and consistent filaments. The primary downside is the difficulty in maintaining uniform diameter, especially at high speeds, and potential material limitations.
Precision Micro-Extrusion
Focuses on producing high-precision micro-components with tight tolerances, suitable for aerospace and microelectronics. The advantage is exceptional precision and detail. The disadvantage includes the high cost of precision tooling and complexity in handling and quality control of such small parts.
Medical Micro-Extrusion
Produces micro-sized components for medical devices, such as catheters and surgical tools. It allows for high-precision and customization to medical standards. However, the process requires stringent quality control and cleanliness, and the materials used must meet strict biocompatibility standards.
Micro-Drip Tubing Extrusion
Specifically for manufacturing micro-drip irrigation tubes. The advantage is the ability to produce highly efficient irrigation systems with precise water delivery. The main disadvantage is the complexity of creating uniform drip points and the potential for clogging, requiring careful design and maintenance.
Micro-Extrusion Materials Available
Each of these materials has its own advantages, limitations, and cost implications. The choice of material and manufacturing technique usually depends on factors like the complexity of the design, required precision, material properties, and production volume.
Canyon Components strives to meet all customer service requests. Feel free to contact Canyon Components engineering and let our knowledgeable staff help you design the perfect part for your needs.
Micro-Extrusion can be performed in a number of ways depending on the composition and intended use of the final product. Some common materials available for Micro-Extrusion include the following.
Elastomers
Elastomers (also referred to as rubber) are a class of materials known for their unique ability to stretch, deform, and return to their original shape, making them essential in a wide range of applications.
PPSU (Polyphenylsulfone)
Polyphenylsulfone (PPSU) Plastic is a high-performance thermoplastic known for its exceptional heat resistance, toughness, and stability under thermal stress. It's widely used in medical instruments, aerospace, and plumbing components due to its excellent chemical resistance and ability to withstand repeated sterilizations.
Polyethylene (PE)
Polyethylene (PE) plastic, renowned for its versatility, is a widely used thermoplastic. It's lightweight, impact-resistant, and has excellent chemical resistance. Commonly used in packaging, containers, and pipes, PE is available in varying densities for different applications, including high and low-density forms.
Nylon (Polyamide, PA)
Nylon, a synthetic thermoplastic polymer, is renowned for its high strength, elasticity, and abrasion resistance. It's versatile, easily dyeable, and used in a wide range of products from textiles and ropes to gears and automotive parts.
Specialty Compliances
Canyon have materials available for O-rings, gaskets, & custom parts with compliances ranging from USP Class VI <87> & <88> for medical applications, to FDA CFR 21.177.2600 grades A through F for different food types, to the various drinking water specifications like KTW and NSF. Whether it's metal, rubber, or plastic, Canyon can meet your needs!
PEEK (Polyetheretherketone)
PEEK plastic, or polyether ether ketone, is a high-performance thermoplastic known for its exceptional heat resistance, chemical stability, and mechanical strength. It's widely used in aerospace, medical implants, and automotive industries for its durability and ability to withstand harsh environments.
ABS (Acrylonitrile Butadiene Styrene)
ABS plastic, a thermoplastic polymer blend of acrylonitrile, butadiene, and styrene, is renowned for its toughness, impact resistance, and rigidity. It's easily machinable and ideal for automotive parts, consumer goods, and 3D printing due to its strength and versatility.
PVC (Polyvinyl Chloride)
Polyvinyl Chloride (PVC) plastic, a widely utilized thermoplastic, is celebrated for its durability, chemical resistance, and versatility. It's commonly used in construction for pipes and fittings, medical devices, and window frames, and can be made more flexible with the addition of plasticizers.
Plastics
Plastics are a broad class of synthetic or semi-synthetic materials known for their versatility and moldability. They are crucial in numerous applications due to their ability to be shaped, lightweight nature, and resistance to chemicals and moisture.
Infinite "Giant" Diameter O-Rings
By either Continuous Molding O-rings, or Splice & Vulcanizing O-rings, Canyon can provide mold-less, infinitely large O-rings at competitive prices!
Polyurethane (PU, AU)
Polyurethane O-rings, gaskets, & custom molded parts generally have two or three times greater tensile strength and wear resistance than Nitrile and comparable polymers. Polyurethane also provides excellent permeation resistance when compared to most rubbers.
