Manufacturers are always seeking out cost-effective, durable, and versatile materials to improve their bottom lines, and plastic extrusions have become a proven solution in doing so across a wide range of industries. At PBS Plastics, we specialize in custom plastic extrusions that help our clients solve unique challenges—whether it’s hitting a specific performance spec, improving aesthetics, or simply cutting costs without cutting corners.
Let’s break down how custom extrusions work and how they can give your next project a competitive edge.
What are Plastic Extrusions?
Plastic extrusion is a manufacturing process that creates continuous shapes, like tubes, channels, or profiles by melting plastic and forcing it through a custom-shaped die. Think of it like squeezing toothpaste from a tube, but with precise, engineered shapes made from thermoplastics like ABS, PVC, or polycarbonate.
These profiles can be tailored to fit very specific needs, from exact dimensions to material properties like flexibility, color, and UV resistance.
Common Applications by Industry
Plastic extrusions are used virtually everywhere. This is largely due to their impressive adaptability in strength, appearance and function—so much so they’re found in more places than most people realize. Some common industries and applications include:
- Construction: Window frames, trim, weather seals, wall corner guards
- Retail & Commercial Displays: Signage edging, display channels, shelving systems
- Automotive: Gaskets, door trims, interior detailing
- Medical: Tubing, protective casings, enclosure profiles
- Office & Education: Framing for whiteboards, partitions, and paneling
Because extrusions can be customized for both performance and appearance, they’re ideal for manufacturers needing large quantities of uniform, functional parts.
Why Choose Custom Extrusions Over Off-the-Shelf Components?
While off-the-shelf components can work in certain situations, they often require extra modifications to outfit your specifications. Custom plastic extrusions, on the other hand, give you full control over shape, size, material, color, and finish. Whether you’re matching a specific brand color, mimicking the look of metal, or needing flame-retardant or chemical-resistant properties, a custom solution ensures a precise fit for your application. Plus, because the extrusion process produces a continuous shape, it can streamline your production process by eliminating the need to assemble multiple parts. That kind of efficiency reduces waste and ultimately saves time and money, especially when you’re producing at high-volumes.
Real Case Studies on Why Customers Turned to Plastic Instead of Metal
In many cases, plastics extrusions can be a practical alternative to metal when cost, weight, or availability are a challenge, but performance is crucial. Here are two examples of how we helped customers make the switch:
A Cost-Effective Alternative for an Aluminum-Like Finish
A customer came to us needing the sleek, modern look of an aluminum trim on their product, much like you’d typically find around whiteboards, but without the need for the structural strength aluminum provides. Using ABS plastic (Acrylonitrile Butadiene Styrene) with a metallic spec-color finish, we delivered a custom plastic extrusion that looked nearly identical to aluminum, at a fraction of the cost.
The result? The client met their aesthetic goals, significantly saved on costs, and avoided the heavier weight and higher shipping fees that come with using metal.
Achieving Strength Without the Expense
In another case, a client did require a substrate that possessed the same strength and durability as aluminum. However, tariffs and sourcing issues made metal less appealing. We recommended a glass-filled plastic material that offered the necessary structural integrity of aluminum while being lighter and significantly more affordable. The end product met performance criteria and saved the client money without compromising on quality.
Custom Plastic Extrusions for Your Unique Needs
These examples highlight our commitment to delivering customized extrusion profiles that add value—whether by enhancing aesthetics, increasing strength, or reducing costs. Our expertise and flexible manufacturing processes allow us to work closely with you to develop solutions that align perfectly with your project goals.
Partner with PBS Plastics for Custom, Cost-Effective Solutions
Whatever your requirements, PBS Plastics is here to provide expert guidance and innovative extrusion solutions that add value to your operations. From initial concept to production, our team works closely with you to find the right material, shape, and finish for your application, at the right price.
Contact us today to explore how our value-added services can help optimize your next project.