Yes. XSP manufactures solid, hollow, semi-hollow, multi-cavity, and large industrial extrusion dies with diameters ranging from approximately Ø70 mm to Ø2,400 mm. We also manufacture extrusion press tooling and supporting components for heavy-duty and high-tonnage extrusion applications.

Our experience covers window and door systems, curtain walls, automotive structures, EV battery trays, heat sinks, solar systems, rail transportation, industrial profiles, specialty alloys, and aerospace-related applications.

To confirm compatibility, please provide:

• Profile drawing or profile sample
• Aluminium alloy
• Press tonnage
• Billet diameter
• Die stack dimensions or die size
• Required tolerances
• Expected production volume

Our engineering team will review the information and recommend the appropriate die structure, material, and manufacturing plan before quotation.

XSP has specialized in aluminum extrusion dies and tooling since 1992 and reports production capacity exceeding 5,000 die sets per month.

We begin engineering before cutting the tool steel.

XSP uses 2D and 3D die design, historical tooling data, and extrusion-flow simulation to evaluate metal-flow velocity, pressure distribution, friction zones, welding-chamber behavior, bearing balance, and potential profile deformation.

The design is then optimized for the actual profile, alloy, press, billet, and production requirements. This engineering process helps reduce common trial problems such as:

• Uneven metal flow
• Profile twisting or bowing
• Dimensional variation
• Poor seam-weld quality
• Surface lines
• Excessive breakout pressure
• Uneven exit speed
• Repeated die corrections

Finished tooling is inspected using CMM and other precision measurement systems against the approved drawings and specified tolerances. Critical internal areas are also hand-finished by experienced toolmakers where automated polishing cannot properly reach.

This combination of simulation, precision machining, inspection, and skilled hand-finishing is designed to improve right-first-time performance and reduce costly press downtime.

Lead time is confirmed after our engineers review the profile complexity, die diameter, number of cavities, steel grade, heat-treatment requirements, precision level, and press-tooling scope.

A simple solid die and a large multi-core hollow or industrial die cannot realistically follow the same production schedule. For this reason, XSP provides a project-specific production schedule with the quotation rather than giving an unreliable universal delivery promise.

Once the order and technical drawings are approved, the project moves through:

1. Engineering and extrusion-flow analysis
2. Material preparation
3. CNC rough machining
4. Vacuum heat treatment
5. Precision grinding and CNC finishing
6. Wire EDM and sinker EDM
7. Bearing and internal-surface finishing
8. Dimensional and hardness inspection
9. Final assembly, protection, and shipment

For time-sensitive projects, please identify the required delivery date in the RFQ. Our production team will evaluate whether priority scheduling or expedited transportation is available.

Our standard material is high-quality H13 hot-work tool steel, For complex profiles, high-output production, special alloys, or demanding operating conditions, premium options may include 1.2344-grade steel and 8407-grade steel.

However, steel grade alone does not determine die life.

Long-term performance depends on the complete manufacturing and operating system, including:

• Steel quality and forging integrity
• Die structure and stress distribution
• Extrusion-flow and bearing design
• Vacuum heat treatment
• Hardness uniformity
• Surface finishing
• Nitriding intervals
• Die preheating
• Billet and container temperature
• Extrusion speed
• Press alignment
• Cleaning and storage practices

XSP performs controlled vacuum quenching and tempering and verifies hardness consistency throughout the tooling. The company’s published manufacturing process includes computer-controlled vacuum treatment and hardness inspection to help maintain toughness, wear resistance, and structural stability under repeated extrusion loads.

XSP provides engineering support during initial trial extrusion and subsequent die correction. When a trial issue occurs, please send the following information:

• Clear photos or video of the full profile running out
• Photos of the profile nose
• Marked dimensional inspection report
• Profile straightness, twist, bow, and flatness data
• Billet alloy and size
• Billet, die, and container temperatures
• Breakout pressure
• Running pressure
• Extrusion speed
• Puller conditions
• Surface-defect photos or videos

Our engineering team will compare the trial results with the approved profile drawing and original die design. We will then identify whether the issue is related to metal-flow balance, bearing conditions, die deflection, temperature, speed, press alignment, alloy behavior, or another operating factor.

Depending on the findings, we will provide:

• Recommended press-parameter adjustments
• Marked die-correction drawings
• Step-by-step polishing or bearing instructions
• Modification recommendations
• Replacement evaluation when a confirmed manufacturing defect is involved The objective is to solve the root cause rather than repeatedly correcting

Yes. XSP supports new proprietary profiles, complex multi-void sections, thin-wall profiles, large industrial profiles, multi-cavity dies, difficult tongue-ratio designs, specialty alloys, and existing profiles that have experienced unstable extrusion performance.

Our engineers can work from:

• Finished profile drawings
• Existing die drawings
• Extruded profile samples
• Previous trial reports
• Dimensional inspection reports
• Photographs of surface or flow defects
• The customer’s press and production parameters

Before manufacturing, we evaluate profile extrudability, material distribution, wall-thickness transitions, tongue ratios, welding-chamber requirements, bearing strategy, die strength, expected output, and press limitations.

Where appropriate, we may recommend minor profile or die-structure modifications to improve:

• Extrudability
• Dimensional stability
• Surface quality
• Seam-weld performance
• Extrusion speed
• Die strength
• Tool life
• Production output

XSP’s published capabilities include digital extrusion-flow simulation, CNC machining, wire EDM, sinker EDM, CMM inspection, and precision hand-finishing for complex die geometries.

XSP stands behind the engineering and manufacturing quality of its tooling.

If a die experiences a serious failure, irrecoverable dimensional issue, or inability to produce the approved profile during the initial trial, our technical team will conduct a root-cause investigation.

The evaluation may include:

• Failure photographs and videos
• Trial-extrusion samples
• Press parameters
• Temperature records
• Dimensional reports
• Hardness or material analysis
• Inspection of the returned tooling, when necessary

If the investigation confirms that the failure resulted from an XSP design, material,

heat-treatment, or manufacturing defect, XSP will provide the appropriate corrective action, which may include repair, modification, remanufacturing, or replacement at no additional tooling cost.

Damage caused by improper preheating, incorrect press parameters, press misalignment, abnormal overload, improper nitriding, unauthorized die modification, incorrect storage, or inadequate maintenance must be evaluated separately.

This technical-review process protects both parties and ensures that corrective action addresses the actual cause of the failure.

Proper maintenance is essential to achieving consistent extrusion performance and long die life. After each production run:

1. Allow the die to cool using a controlled Avoid uncontrolled thermal shock.
2. Remove residual aluminum using the extrusion plant’s approved caustic-cleaning
3. Thoroughly rinse, neutralize, and dry the
4. Inspect bearings, bridges, ports, welding chambers, mating surfaces, and support
5. Correct minor damage, aluminum pickup, roughness, or bearing wear before the next
6. Record the die’s production quantity, operating condition, correction history, and nitriding
7. Re-nitride according to the die condition, alloy, production volume, and established maintenance schedule.
8. Apply suitable rust-preventive protection to exposed steel
9. Store the die in a clean, dry, organized environment away from moisture and corrosive

Dies should not be stored with aluminum residue, caustic solution, or moisture remaining inside the ports and welding chambers. Good maintenance records also allow the extrusion team and die supplier to identify performance trends before a serious failure occurs.