Profile Extrusion FAQs

You’re not the only one with questions about the extrusion process. That’s why we developed this list. You’ll find answers to the most common extrusion-related questions we’ve heard over the past few decades; and we’ve heard a lot!


Jump to a section using the links below, or simply scroll down to spark your curiosity.


General FAQs

What are your capabilities?

65 extrusion & co-extrusion lines

  • Hollow profiles, living hinges
  • Dual and multi-durometer
  • Two or more colors

Secondary operations

  • Insert and overmolding (corners and sections)
  • Thermal bending
  • Welding (ultrasonic, hot plate)
  • Lamination
  • Assembly
  • CNC routering

In-line processing and fabrication

  • Wire and metal carrier reinforcement
  • Tape (PSA, foam-backed)
  • Slipcoat application, including silicone
  • Flock application
  • Graining
  • Inkjet printing

Advanced testing laboratory

  • Tensile/elongation testing
  • Flowability
  • Hardness (rockwell)
  • Cold impact
  • Component-level validation
  • CMM
  • Dimensionals

In-house tooling design and build

  • Extrusion and co-extrusion dies
  • Trim/fabrication tooling
  • Assembly fixtures
  • Quality gauges

Rapid prototyping

  • FEA
  • Process simulation
  • 3D printing
  • Dedicated prototyping lines

What certifications do you have?

What materials do you work with?

  • TPV
  • TPR
  • T TPO
  • TPE
  • TPU
  • 50+ engineered resins!

For a complete list, please visit our Materials page. If you need help choosing the best material for your unique application, we can help! Contact us online or learn more about material selection in The Engineer’s’ Guide to Selecting an Extruded Seal Material.

How do I design an extrusion profile?

How much does extruded plastic cost?

My project requires an NDA. How do I submit that?

Seal FAQs

What material is best for sealing?

How can I prevent seals from buzzing, squeaking, and rattling (BSR)?

Buzzes, squeaks, and rattles (BSRs) are 100% preventable, yet they remains a major source of warranty claims. This is typically the result of improper material friction characteristics, chemical reactions, and/or environmental factors.


To prevent seal chatter, take a look at the surrounding system.

  • To what, and how, will the seal be attached?
  • What is its proximity to other components?
  • Will it be exposed to extreme temperatures, chemicals, or ozone?


Once you have an understanding of the application’s environment, you can predict potential BSRs and determine the best method of prevention. Some of the most common solutions include the application of a slip-coat, blending a slip-agent directly into the seal material, and applying flock tape or spray to exposed surfaces.

How can I prevent a rubber seals from staining or bleeding?

Staining and bleeding have long plagued rubber seal applications. Fortunately, you can prevent it.


Staining happens when additives in the rubber have some solubility with a mating surface; such is the case with the infamous rubber-footed table stain in the linoleum-floored kitchen. You can prevent this by creating a barrier between the mating materials.


Bleeding is the seepage of rubber additives, namely oils. There are some rubber compounds that are resistant to bleed, but the only way to prevent it entirely is to use an alternative material such as TPV.

What is the white powdery substance that builds up on the surface of a rubber part?

This phenomenon is referred to as “blooming,” and occurs when compounding agents in the rubber migrate, or bloom, to the surface. This is due to the agents’ limited compatibility with the rubber elastomer. It affects the tensile strength, adhesion properties, and appearance of your part.

What are the alternatives to rubber seals?

Depending on your seal application, you may have numerous alternatives to rubber. The most common is TPV, a rubber-like material that can be processed and recycled like plastic, but without the stain, smell, and blooming you see with rubber. It’s like a simplified rubber, allowing for more flexible part design, quicker manufacturing, reduced part/system costs, and weight reduction. Some other alternatives to rubber include TPO, TPU, TPZ, and PVC among others. To help you navigate the sea of options, we’ve developed the The Engineers’ Guide to Selecting an Extruded Seal Material.

Learn More

Contact us today to learn more about the extrusion process and Gemini Group℠’s profile extrusion division.