Rigid-Flexible Co-extruded Profile with Integrated Sealing Function
- Challenges Resolved
- 4
- Processes Applied
- 2
- Production Steps
- 6
01 · Project Background
Understanding the Client's Requirements
A customer required a continuous profile that combined a rigid structural section with a flexible sealing section. Using separate rigid and flexible components would require additional assembly and could complicate alignment along the profile length. OKAWA evaluated a soft-hard co-extrusion solution to integrate both functions into a single continuous profile.
02 · Manufacturing Challenges
What Made This Project Technically Demanding
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Combining rigid and flexible materials within one continuous profile
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Maintaining a stable interface between materials with different mechanical properties
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Controlling the geometry of both structural and flexible sections
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Maintaining consistent flexible-section performance along the profile length
03 · OKAWA Solution
How We Engineered the Answer
OKAWA reviewed the profile structure and functional requirements to determine suitable rigid and flexible material zones and evaluate material compatibility for co-extrusion. The tooling was designed to control the flow and positioning of the two materials within a single profile. During sample development, attention was given to the interface between the rigid supporting section and the flexible sealing section, as well as dimensional stability after cooling. By integrating both functions during extrusion, the resulting profile can simplify downstream assembly and provide a continuous sealing or cushioning feature along the finished component.
04 · Production Flow
Step-by-Step Manufacturing Process
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Step 01
Functional Requirement Review
Define the structural and flexible zones according to the product application.
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Step 02
Material Compatibility Evaluation
Evaluate rigid and flexible material combinations for processing and interface performance.
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Step 03
Co-extrusion Tooling
Develop tooling to control the flow and geometry of both material sections.
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Step 04
Sample Production
Produce trial profiles and evaluate the rigid-flexible interface and overall geometry.
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Step 05
Process Adjustment
Optimize material flow, cooling and sizing for stable continuous production.
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Step 06
Cutting & Inspection
Cut finished profiles and inspect critical dimensions and functional sections.
05 · Delivery Results
Final Outcomes & Project Value
The final profile integrated rigid structural support and a flexible functional section into one continuously extruded component. Following sample verification, the process was prepared for repeatable production, providing the customer with an integrated profile that can reduce separate component handling and downstream assembly.