Extrusion tooling is at the heart of every profile production process. It determines the geometry, surface quality and dimensional accuracy of every profile leaving the line. At SLS, this tooling is not purchased externally but developed, manufactured, coated and maintained in-house. A team of 18 employees – including one apprentice currently in training – covers the entire process: from CAD design and precision machining through to maintenance during ongoing production.

From CAD design to initial sampling

The development process for new extrusion tooling begins on screen: designers develop the tooling using CAD software, taking profile geometry, material flow and manufacturing requirements into account from the planning stage onwards. From this digital design, the process moves directly into manufacturing – all steps are coordinated with one another, and handovers between departments are reduced to a minimum.

The result is a short lead time: at SLS, it often takes only a few weeks from the initial design to the finished sample part. This allows new profiles to be sampled quickly and transferred into series production – a clear advantage for customers developing under time pressure or wishing to test different variants.

Machinery: CNC milling centres, EDM machines, in-house assembly

The machining capabilities of the SLS toolmaking department cover the full range of modern precision manufacturing. CNC milling centres enable highly accurate machining of complex tooling geometries. Electrical discharge machining (EDM) is used where conventional machining reaches its limits – for example, where tight tolerances, hardened materials or fine internal geometries are involved. Final assembly takes place in the in-house workshop, where all components are adjusted and matched to the intended production line.

The range of tooling extends from the smallest precision components to complex large-scale tools. The use of high-quality materials is not a question of additional expense, but of economic efficiency: only precisely manufactured tooling made from suitable materials delivers consistently high-quality results over long service lives.

Hard coatings for long tool life

To maximise tool life, the tooling is provided with special hard coatings. These coatings protect the tool surfaces against wear and maintain sharp contours over extended periods, even at high throughput volumes. This reduces the frequency of tool changes and helps maintain consistent profile quality during ongoing production.

Maintenance and servicing: tooling always ready for use

Unplanned tool failure means production downtime. SLS addresses this risk through a consistent maintenance and servicing regime: tooling is inspected regularly, and wear parts are replaced proactively before they cause problems. As an additional safeguard, the most important tools are insured. Because toolmaking and production are located in close proximity, any necessary adjustments or repairs can be carried out quickly and without dependence on external providers.