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What is Custom Silicone Extrusion? Process and Applications

Author: YiNuo Zhang
Published on: 2024-02-25

“The custom silicone extrusion process is integral to creating high-quality, durable, and precisely shaped silicone parts. It caters to a diverse range of industries, from automotive to medical. “

Silicone is a synthetic polymer made from silicon, oxygen, carbon, and hydrogen. This material is known for its remarkable flexibility, heat resistance, and chemical stability. Meanwhile, you can find several manufacturing methods to convert these valuable properties into functional applications. Among them, Custom Silicone Extrusion is a prominent one. It involves forcing silicone rubber through a shaped die to create continuous profiles of specific shapes and sizes. Subsequently, this method allows for the production of highly customized silicone components.

This article will explore custom silicone extrusion in detail, including process, applications, and more. 


What is Silicone Material?

Silicone is a synthetic polymer, and its structure centers around silicon-oxygen chains, with silicon atoms also bonded to carbon-containing groups. This dual nature gives silicone unparalleled flexibility and resilience.

The silicone materials offer excellent elastic properties which makes them suitable for diverse sealing or gasket applications. It is also resistant to chemicals and impact loads. Thus, various manufacturing techniques are employed to create the silicone parts or products. Some examples are silicone injection molding, compression molding, silicone extrusion, etc. 

Other useful properties of Silicoe are;

  • UV-resistant
  • Bio-compatible 
  • Optically transparent
  • Excellent elongation properties 

Next, we will discuss how Custom Silicone Extrusion is used to utilize these properties by manipulating the raw silicone rubber into desired components.

Related: Silicone Injection Molding: Process, Advantages, and Applications


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What is Custom Silicone Extrusion?

Do you know how silicone medical tubes are made? Typically from the Silicone Rubber Extrusion. Here, customization is needed in this application or many more cases to create custom-need silicone profiles. 

Moreover, the Custom Silicone Extrusion has some standard custom shapes like D, L, H, and Wedge profiles.

Silicone extrusion 

Like any other Rubber Extrusion Process, it involves an extrusion die to shape the while forcing silicone rubber through it. Consequently, the automated Silicone extruder machine can automatically feed the silicone strips into the die.

Custom Silicone Extrusion Process

The silicone-shaped extrusion of custom parts or products involves several steps. The process starts with the design of a custom silicone extrusion die and machining it with a CNC machine or EDM. The material for the die is typically steel or aluminum.

Here is the step-by-step Custom Silicone Extrusion Process;

Step Description
Design and Tooling Design the die for the desired profile, and manufacture with precise tolerances.
Material Selection Selection of silicone rubber based on desired properties set 
Mixing and Blending The blending of raw silicone with catalysts and colorants to achieve desired properties.
Extrusion Pushing through the die and extruding with crosshead to form the profile.
Curing Silicone undergoes curing using heat. 


Silicone extrusion process 

Additionally, Custom extrusion allows to extrude more than one type of silicone material. 


  • Single Extrusion: One type of silicone material is extruded 
  • Co-extrusion: Two different silicone rubbers for a single profile
  • Ti-extrusion:  Extrusion of three Silicone rubbers


The Automotive Applications of Custom Silicone Extrusion

Custom silicone extrusion has extensive applications in the automotive industry. It offers significant benefits that enhance vehicle performance, safety, and longevity. Its ability to withstand extreme temperatures, resist chemicals, and maintain flexibility under pressure makes it suitable for many automotive applications. This resilience ensures that components can endure the rigors of daily operation without compromising the vehicle’s integrity.

Silicone extruded seals and gaskets 

Through these applications, custom silicone extrusion advances automotive technology, offering solutions that improve vehicle durability, performance, and passenger comfort.

  • Seals and Gaskets
  • Hose and Tubing
  • Weatherstripping
  • Vibration Damping
  • Trunks
  • Insulation for Wires & Cables

Related: Exploring Manufacturing Methods for Automotive Fasteners


What are the Applications of Custom Silicone Extrusion?

Silicone extrusion parts 

The utility of custom silicone extrusion spans various sectors, from aerospace to healthcare. It offers solutions that meet specific environmental and operational challenges. Below, we present a table that outlines the industries benefiting from custom silicone extrusion.

Table: Custom Silicone Extrusion Applications

Industry       Applications
Aerospace       Seals, gaskets, insulation blankets, hose & duct systems, vibration dampening
Automotive       Door seals, window gaskets, engine gaskets, hose, vibration dampening pads
Medical       Tubing for fluid transfer, seals for equipment, catheters, and implantable devices.
Electronics       Seals for enclosures, insulation for wiring, grommets, and protective sheathing.

Furthermore, the Custom Silicone Extruded Parts are less costlier if they are simple in shape because of less cost for die manufacturing. On the other hand, the cost of Silicone Compression Mold or Injection Mold is higher. 


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What are the Advantages of Custom Silicone Extrusion?

This method offers flexibility, durability, and efficiency, making it a preferred choice for industries requiring precise silicone profiles. The advantages of custom silicone extrusion include:

  • Customization: Tailored to meet specific design requirements.
  • Durability: Silicone products are known for their long-lasting properties.
  • Efficiency: Streamlines production, reducing time and costs.
  • Versatility: Suitable for a wide range of applications.
  • High Performance: Excellent thermal, chemical, and electrical resistance.
  • Eco-friendly: Silicone is a sustainable material option.
  • Low Maintenance: Requires minimal upkeep, reducing long-term costs.

Moreover, the efficiency of the custom extrusion process significantly reduces production time and costs. It is particularly advantageous for companies looking to optimize manufacturing operations and minimize waste.


Silicone Rubber Extrusion Vs Silicone Injection Molding

Silicone injection molding part

Injection molding is another technique for silicone parts, especially it can mold Liquid Silicone Rubber that can not be molded with the extrusion process. The Injection molding of silicone rubber involves injecting the molten form of the mixture( Silicone polymer, catalysts, and additives) to die at high pressure.

Parameter Silicone Rubber Extrusion Silicone Injection Molding
Cost Generally lower initial tooling costs but can vary with complexity. Higher initial tooling costs due to complex molds, but cost-effective at high volumes.
Suitability for Different Volumes More cost-effective for continuous profiles in small to medium volumes. More suited for high-volume production due to mols and tooling cost. 
Complexity Consistent cross-sections It can produce complex shapes with intricate designs and inserts. 
Precision & Tolerance Good precision Excellent precision and tighter tolerances 
Material Efficiency High material efficiency with minimal waste Relatively more waste due to runners, gates, and sprues.
Finish & Appearance Generally smooth finish Quality finish and requires minimal post-processing.


Case Study on Prolean Custom Silicone Extrusion Services

Protean is a China-based manufacturing firm that provides comprehensive solutions for silicone extrusion. This case study is for Prolean’s capabilities, applications, and the transformative impact of custom silicone extrusion services.

Custom Silicone Extrusion Capabilities

Prolean’s expertise in silicone extrusion is vast, offering a range of capabilities that ensure tailored solutions for every project. The proficiency extends to single, co-extrusion, and tri-extrusion processes. Next, the extrusion facility is capable of handling profiles from the minuscule 0.010” to 3” in cross-section.

  • Diverse Extrusion Processes: Prolean can integrate various materials and colors into a single product, from multi-lumen to multi-durometer and multi-color extrusions. 
  • Custom Formulations: Tailoring mechanical, chemical, temperature, and electrical properties to specific requirements for optimal performance and cost-effectiveness for each product.

Stringent Quality and Compliance Standards

The manufacturing processes at Prolean follow strict quality control measures and compliance with international standards. Certifications such as ISO 9001:2015, and FDA 21CFR177.2600. 

  • Certifications and Standards: Compliance with critical industry standards reflects a commitment to quality and reliability.
  • Customized Solutions: Through detailed attention to detail, Prolean ensures that each product meets the stringent requirements of its diverse clientele.

Dedication to Customer Achievement

ProleanTech prioritizes customer fulfillment above all. Through tailor-made solutions and joint design efforts, Prolean guarantees superior quality and customer triumph. Meanwhile, the production team partners with the customer. So, they can understand their unique requirements to craft silicone products.

China Custom Automative Part Silicone Extrusion at Prolean

Prolean excels in delivering custom silicone extrusions for automotive parts. The China Custom Automative Part Silicone Extrusion services are for the global market. Basically, they cater to the automotive industry’s evolving needs. 

  • Precision-Crafted Solutions: Prolean’s expertise ensures each silicone extrusion meets the stringent requirements of automotive applications.
  • Innovative Approach: Prolean introduces cutting-edge solutions for the automotive sector in China by adapting to industry changes. 
  • Market-Specific Focus: The R&D team understands the unique demands of the automotive market to customize automotive components for optimal performance.

Read more:


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Summing Up

Custom silicone extrusion represents a pivotal innovation in manufacturing. It provides excellent versatility, efficiency, and quality in product development. Its ability to produce customized, durable, and high-precision components makes it indispensable across various industries. 

Prolean’s Extrusion services further enhance this field, providing a comprehensive approach to manufacturing that meets the evolving needs of businesses and consumers. 



What makes custom silicone extrusion unique?

Custom silicone extrusion is unique due to its ability to produce highly customized, precise, and durable silicone rubber parts efficiently and cost-effectively.

Can custom silicone extrusion be used for medical devices?

Yes! Its biocompatibility and resistance to extreme conditions make it ideal for medical devices.

What are the key considerations in selecting silicone material for extrusion?

Key considerations include the application’s requirements for elasticity, tensile strength, and temperature resistance.

How does the custom die affect the extrusion process?

The custom die determines the shape and size of the extruded silicone, playing a crucial role in achieving the desired product specifications.

What industries benefit most from custom silicone extrusion?

Industries such as automotive, healthcare, electronics, and construction benefit significantly due to the versatility and durability of extruded silicone products.

How does Prolean’s Aluminum Extrusion Services complement silicone extrusion?

Prolean’s services provide integrated manufacturing solutions, enhancing the capabilities and applications of silicone extrusion in product development.



  1. Verheyen, F., Giesen, R.-U. (2017).. The extrusion process of high-consistency silicone rubber. In Silicone Elastomers World Summit 2017. Nordmann Rassmann GmbH; Universität Kassel. Retrieved from https://www.researchgate.net/publication/332466979_The_Extrusion_Process_of_High-Consistency_Silicone_Rubber 
  2. Acharya, D. (2024). Silicone injection molding: Process, advantages, and applications. ProleanTech. Retrieved from https://proleantech.com/silicone-injection-molding/


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