Many engineers are unaware that extrusion can offer huge advantages over many alternative techniques such as machining, roll forming, and milling. We're pleased to explain how this technique could improve your product or production process and why it will often save you time and money!
Read on and we’ll set out how we can help you optimize your product.
What is precision aluminium extrusion?
Put simply: the aluminium is heated in a kiln until it is soft enough to be formed. The temperature varies per alloy and is very important for the final result. The hot aluminium is then pressed under great pressure through a mould that determines the final shape of the profile. Once the profile has been extruded, it is cooled, stretched, hardened, and cut to size, after which any necessary finishing can be applied.
Examples include milling, drilling holes and surface treatments. The profile can then be assembled into a finished or semi-finished product. This is how our aluminium extrusion profiles are made.
The animation below shows how the process works.
Compare extrusion companies
Before delving deeper into the world of extrusion, let's start with a short introduction to the various providers.
It’s important to know that not every extruder (extrusion supplier) can or will offer you what you need. Many companies in this industry focus on pressing large quantities of aluminium. Mifa, on the other hand, focuses mainly on high quality, complex profiles. We don’t make things unnecessarily complex, but a complex profile is often the part in a product that can make a difference. This could be because it has a complex shape, has to be very thin-walled or may have a maximum dimensional tolerance of just ±0.02 mm. This is precisely the level of detail that Mifa excels in.
The range of different alloys also makes Mifa unique! With fourteen alloys, including magnesium, we have a wide range to offer. We also extrude many other alloys on request. We’ll be pleased to advise you on this.
Advantages of aluminium extrusion profiles at Mifa
- Considerable freedom of form in the design process
- Cost savings compared to many production techniques
- Access to our extensive knowledge and experience
- We manufacture total products by machining, surface treatment and assembly in house
- Tolerances from ±0.02 mm
- Wall thicknesses from ±0.25 mm.
- Profile weight from 0.003 kg/metre tot 10 kg/metre
- Profile dimensions from Ø 3 mm to Ø 180 mm / 220 x 60 mm
By using high-end precision, Mifa can produce the most complex designs for aluminium extrusion profiles. No matter how complicated your designs may be, an extrusion mould is relatively cheap and easy to make (compared to moulds of other techniques). This makes precision extrusion a cost-effective alternative to machining, for example.
Curious how Mifa can help you?
We hope we have given you a clear view of of the advantages of custom aluminium extrusion at Mifa. If you have any questions, or if you need further information, don't hesitate to contact us. We are happy to help you!
Designs of Mifa's extrusion profiles
Our technology gives you a huge amount of freedom of design. The precision offered by Mifa means that designers can truly let themselves go at their drawing tables. The unprecedented options offer a world of freedom. Designers make no concessions when designing profiles. At the drawing table, they have no need to worry about restrictions or standards. This freedom of form produces excellent end results.
With the extensive experience of Mifa's engineers, we’ll be pleased to assist you in your design process. This enables you to get the best out of your products. Our engineers will be pleased to help you. Co-engineering often results in the best products, in which Mifa’s knowledge on extrusion enriches your product knowledge.
From extrusion to machining, surface treatment, and assembly
As we have seen, extrusion at Mifa goes much further than simply pressing aluminium. From profile to product, we offer you maximum relief within the supply chain! We assist our customers from co-creation to assembly and logistics.
For more information, download our whitepaper.
Sustainability: Top of mind at Mifa
The environment is of great importance to us. We therefore strive to continuously reduce our ecological footprint. To achieve this, Mifa takes into account factors such as: energy consumption, waste management, vitality, safety and health of employees. Mifa has taken the following actions concerning sustainability:
New sprinkler system: protects people and the environment against an incipient fire. Sprinklers also limit the amount of toxic gases that emerge during a fire.
Prevention of waste: the use of sustainable cardboard cups prevents material wastage. Mifa also has its own recycling zone where we separate raw materials, making it easier to recycle. In this way, we also reduce energy consumption.
The energy consumption to produce aluminium is high. However, aluminium has a very long lifespan. No less than 75% of the aluminium ever produced is still in use according to The International Aluminium Institute.
Masterclass on aluminium production methods
Because designers and engineers are often insufficiently aware of the possibilities offered by extrusion, we offer masterclasses so that they can increase their knowledge and understanding of the options. This makes it possible for you to design the best possible aluminum profile. We give a number of 'standard' masterclasses, both at our own premises and at customer locations, but we’re also more than willing to tailor the content of a masterclass to your needs or issues!
Please contact Frank Loobeek or see our page on masterclasses.
Business Development Manager Industry
The heart of our business: precision extrusion
Mifa has been the benchmark for decades when it comes to extrusion. Everything in our company is focused on optimizing the product and processing it into a top-quality item.
To this end we regularly renew or improve our presses and broaden and improve our range of machinery with everything needed to improve the production process. From a five-axis CNC machine to the fully robotized production of front forks for KTM.
Our technology, knowledge, and experience enable us to produce highly complex aluminium profiles. However, profiles out of other materials like magnesium can be produced with an accuracy of up to ±0.02 mm. We also outperform the standard when it comes to straightness, torsion, concentricity, parallelism, surface roughness, and fit. This often results in no further processing being necessary, saving you costs.
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Case: Train modernization at NedTrain
NedTrain wants to modernise its famous double-deck trains. This means that all trains will be completely dismantled and then reassembled. Mifa supplies extruded floor profiles for this purpose. Because most of the profiles are beneath the floor, they are only partially visible or not visible at all.
This project is a European tender. This means that every company has the opportunity to apply for this public contract. Of all the companies that participated, Mifa was ultimately chosen for this project. One of the main reasons for this, is that Mifa has all the required technologies for Nedtrain's project in-house. These are:
- CNC machining
- Surface treatment
Case: Atlas project at Cern, Geneva
The Max Planck Institute of Physics is a state-of-the-art research institution whose discoveries have had a major impact on the world of electronics. Within the framework of the Atlas detection project, the Max Planck Institute of Physics is developing particle accelerators intended for the Geneva-based CERN organisation.
The ATLAS project requires absolute precision in all areas. For this reason in particular, the Max Planck Institute of Physics has chosen aluminium profiles from Mifa. Current standards for extruded aluminium profiles usually allow deviations of 0.15 mm. Mifa offers extrusion processes with an accuracy of 0.02 mm. This is why the Max Planck Institute of Physics chose Mifa as a partner for this demanding project.
Case: Contribution to ETAP lighting technology
ETAP Lighting (Belgium) creates user-friendly and sustainable lighting. The company specialises in creating lighting comfort in the workplace. Etap's products reduce electricity consumption to a minimum. The company has a total of about 500 employees and operates in eleven countries.
Mifa has made an important contribution to the 'D3 Downlight LED', a new model of LED application. This project was brought to a successful conclusion by means of co-engineering. Mifa was involved from the design phase to the development of the prototype and series production.
Get in touch with Mifa
Would you like to receive more information on our aluminium profile designs? If so, please complete the contactform. You’re also welcome to call Mifa's staff at any time on: +31 (0)77 – -389 88 88.