Advantages of Impact Extrusion Explained Simply
Are you considering manufacturing new parts using impact extrusion? Do you want to produce durable metal parts without material waste and expensive rework? Learn how impact extrusion helps you economically and sustainably produce precise, long-lasting components.
Impact Extrusion: What Is It?
Impact extrusion is a cold bulk forming technique where metallic materials are plastically deformed at room temperature under high pressure. Instead of removing material, as in milling or turning, it is pressed into shape—without chipping and waste. This results in extremely strong, precise, and material-efficient components—ideal for series production and demanding applications.
The Key Advantages of Impact Extrusion at a Glance
- Minimal Material Loss: Nearly 100% of the raw material is utilized
- High Strength: More stable components through densified material and intact fiber structure
- Exact Dimensional Accuracy: Tolerances in the tenth to hundredth range—even with large quantities
- Less Rework: Parts are often ready to install without additional machining like turning, milling, or grinding
- Low Energy Use: Processing at room temperature saves power and process heat
- Economical for Series: Fast, automated production reduces the unit cost from about 50,000 components
The Detailed Advantages of Impact Extrusion
Technical Advantages
Very precise shapes—even with large quantities
The component is shaped under pressure with special tools—always the same. So parts that are exactly repeatable are created, e.g., with deviations under 0.1 mm. Ideal for when many parts need to fit together precisely later—such as in the automotive or medical sectors.
Very stable components—no “break through weakness”
In impact extrusion, the metal is compacted without cutting or separation. This means there are no “predetermined breaking points” inside. The components therefore last longer and are more resistant to stress, shocks, or vibrations.
Even Difficult Shapes Feasible—from One Piece
With different press directions (e.g., from the front, back, or sides), hollow shapes, sleeves, or special forms can be created—without needing to weld or screw multiple parts together.
Economic Advantages
No Waste—You Use Almost 100% of the Material
Unlike milling or turning, no material is cut away in impact extrusion. So there is hardly any offcuts or scrap. This is especially cost-efficient with expensive materials like stainless steel or copper
Less Rework—the Part is Directly Usable
In many cases, the component is finished after the pressing process. This means: No additional milling, turning, or grinding needed. This saves you time in production and also reduces tool costs.
Good for Large Quantities—at Low Cost per Part
Once the tool is built, production runs rapidly and automatically. This significantly lowers the cost per component—especially for medium and large series of 50,000 pieces per year.
Sustainability & Environment
Lower Energy Consumption—No Heat Required
In impact extrusion, the metal is processed cold—without an oven, without annealing. This process requires significantly less electricity or gas compared to other methods where the material must be preheated.
Minimal Metal Waste—Low Rejections
What goes in at the front comes out as a finished part at the back. This saves raw materials and protects the environment—especially with valuable metals like copper or aluminum.
Shorter Process Chains—Less Rework, Less Transport
Because the component can often be used without further processing, additional process steps or transports between multiple production stations are eliminated.