Custom Profile Extrusion
Advanced Blow Molding for Complex, Cost-Efficient Thermoplastic Designs
Mercury Plastics’ proprietary Air-Core® blow molding process unlocks geometries and design possibilities that conventional blow molding simply cannot achieve. Whether you need a molded feature added in the middle of a tube or a multi-geometry component that eliminates fittings and reduces assembly time, Air-Core® provides a smarter, more flexible path to performance.
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What is Custom Profile Extrusion?
A Flexible Alternative for Complex Thermoplastic Parts
Custom profile extrusion enables the continuous production of complex thermoplastic profiles and tubing with precise cross-sectional geometry and tight tolerances. This process offers design flexibility, broad material options, and cost-effective manufacturing for complex parts.
With Mercury Plastics’ extrusion capabilities, we can:
- Create complex profiles and tubing in a single, continuous process
- Select from a wide range of rigid and flexible thermoplastics
- Reduce assemblies, fittings, and tooling complexity
Custom profile extrusion delivers lighter, more manufacturable, and highly reliable components from prototype through high-volume production.
Extrusion Applications
Mercury Plastics provides custom profile extrusion, tubing extrusion, and co-extrusion to support a wide range of thermoplastic components.
Typical extrusion applications include:
- Continuous profiles and tubing requiring precise cross-sectional control
- Parts designed for in-line operations such as cut-to-length, punching, printing, or tape application
- Extruded components intended for downstream fabrication processes
- Profiles requiring post-extrusion welding, forming, drilling, or punching
Many extrusion programs combine extrusion with Mercury Plastics’ in-line operations and post-extrusion fabrication to create fully finished, production-ready components.
Core Thermoplastic Processes Under One Roof
Mercury Plastics is unique in offering all plastics and e-beam capabilities under one roof: extrusion, Air-Core® molding, forming, fabrication, injection overmolding, industrial-polymer modification, and bioburden reduction. This eliminates fragmentation and enables faster iterations from concept to finished part.
Our engineering teams frequently combine extrusion with:
Air-Core® Molding
Beginning with a tailored profile or tube, Air-Core® can introduce molded features at precise locations along the length.
Forming & Fabrication
After extrusion, tubing can be thermoformed into complex routed shapes, avoiding the need for joints or fittings.
Injection Overmolding
Overmolding creates leak-free joints and end details without adhesives, clamps, or heat sealing.
Electron Beam Crosslinking
Crosslinking enhances thermal, chemical, and mechanical performance of polyethylene, TPE, and other compatible materials, extending product life and improving structural integrity.
Engineering Support from Start to Finish
Our engineers collaborate with you early—using SolidWorks®, Moldflow®, FEA, prototyping, and our in-house machine shop—to optimize manufacturability, reduce cost, and achieve performance targets.
Why Choose Mercury Plastics?
A Partner for Complex, Multi-Step Thermoplastic Programs
Deep Engineering Expertise
Decades of experience across molding, extrusion, forming, and crosslinking—plus advanced modeling and analysis tools—help us solve design challenges early in the process.
High-Performance Manufacturing
Extrusion is not an isolated capability; it’s part of a seamless system that gives customers a single path from concept to completion.
Continuous Innovation
From advanced extrusion and overmolding techniques to our high-energy electron beam crosslinking, Mercury Plastics is committed to engineering solutions that reduce cost, improve reliability, and enhance product performance.
ISO-Certified Quality
Our ISO 9001:2015 registered Quality Management System reflects the rigorous controls and testing customers expect in critical applications.
Thermoplastics Resources & Education
Get Started with Mercury Plastics
Discover how Mercury Plastics can help you improve product performance, reduce costs, and accelerate time-to-market.
