Since our start in 1993, BD Custom Manufacturing has been dedicated to creating high-quality plastic profile extrusion products designed to meet any set of specifications. We offer an extensive customization process that allows us to provide custom-molded PVC and polyethylene products for a growing number of manufacturing sectors across the country, including:
• RV industry
• Construction industry
• Upholstery and furniture industry
• Marine industry
• Automotive industry
• Point of purchase display
• Sign companies
• Exhibit manufacturers
• Building products
• Consumer goods
Plastic extrusion is an intricate process that involves melting plastic and reconstituting it into a specified configuration. Plastic materials are poured into a hopper, which then feeds the material into a heated barrel.
Next, the melted plastic passes through a screen and into a die that shapes it according to the desired specifications. Plastic extrusion is a popular choice for many different manufacturing applications because it allows for large production volumes at relatively high speeds with low production costs. Some common plastic products made by extrusion include piping and tubing, window frames, weather stripping, and wire insulation.
Customers from all industries have come to rely on BD Custom Manufacturing for our impressive custom-designed tooling, ability to perform small runs, and fast turnaround times. We specialize in the production of custom polyethylene and PVC profiles and offer a diverse selection of configurations, colors, thicknesses, and lengths.
This versatility allows us to manufacture products to meet your exact specifications, no matter how complex. We have the manufacturing capabilities to handle projects of any size, large or small.
Our experienced personnel, high standards of quality control, and constant process improvement enable us to consistently meet or exceed the plastic profile extrusion needs of our customers. As extrusion technologies are constantly evolving, you can count on us to offer the most cutting-edge plastic extrusion methods and materials. As one of our valued customers, you can expect:
• Quick lead times: We are committed to providing quick lead times to ensure our customers receive their orders as fast as possible. Once we receive an order accompanied with a die, you can expect a lead time of approximately 10 working days.
• High-level quality control: Quality control practices are embedded in all aspects of our manufacturing operations. We are constantly improving our processes to ensure that each manufactured part meets the highest level of accuracy and precision. Our goal is to protect you from the inconveniences and delays associated with manufacturing dilemmas and faulty parts.
• Expert tooling design capabilities: If you are starting a new project or would like to replace your current tooling, we have the resources and expertise necessary to design a high-quality extrusion die according to your exact specifications.
• Access to vacuum calibration tooling: We offer vacuum sizing dies and tooling to produce plastic parts with complicated or dimension-critical design features. The vacuum sizing process applies vacuum pressure to the external surface of the plastic profile during the calibration process, allowing for the formation of a consistent plastic part that meets predetermined specifications. This procedure is often used to ensure roundness, such as with the extrusion of tubing, and for producing parts that require a true 90-degree angle.
One of our core strengths as a plastic profile extrusion company is our dedication to going above and beyond to satisfy our customers. We take pride in our ability to think outside of the box to provide innovative solutions for the most complex customer challenges.
By relying on PVC for some applications and Polyethylene for others, BD Custom has the ability to manufacture very specific products for each industry, product and customer request.
If a die can be made, BD Custom Manufacturing can run it.
In a market where the two most popular colors may be black and white, BD Custom Manufacturing extrudes a variety of different colored PVC and polyethylene to meet the demands of an ever growing market.
Flexible PVC coated wire and cable for electrical use has traditionally been stabilized with lead but these are being replaced, as in the rigid area, with calcium based systems.
Liquid mixed metal stabilizers are used in several PVC flexible applications such as calendared films, extruded profiles, injection molded soles and footwear, extruded hoses and plastisol’s where PVC paste is spread on to a backing (flooring, wall covering, artificial leather). Liquid mixed metal stabilizer systems are primarily based on barium, zinc and calcium carboxylates. In general liquid mixed metals like BaZn, CaZn require the addition of co-stabilizers, antioxidants and organophosphates to provide optimum performance
Regular PVC (polyvinyl chloride) is a common, strong but lightweight plastic used in construction. It is made softer and more flexible by the addition of plasticizers. If no plasticizers are added, it is known as uPVC (unplasticized polyvinyl chloride), rigid PVC, or vinyl siding in the U.S. In Europe, particularly Belgium, there has been a commitment to eliminate the use of cadmium (previously used as a part component of heat stabilizers in window profiles) and phase out lead based heat stabilizers (as used in pipe and profile areas) such as liquid autodiachromate and calcium polyhydrocummate by 2015. According to the final report of Vinyl 2010 cadmium was eliminated across Europe by 2007. The progressive substitution of lead-based stabilizers is also confirmed in the same document showing a reduction of 75% since 2000 and ongoing. This is confirmed by the corresponding growth in calcium-based stabilizers, used as an alternative to lead-based stabilizers, more and more, also outside Europe.
Tin based stabilizers are mainly used in Europe for rigid, transparent applications due to the high temperature processing conditions used. The situation in North America is different where tin systems are used for almost all rigid PVC applications. Tin stabilizers can be divided into two main groups, the first group containing those with tin-oxygen bonds and the second group with tin-sulphur bonds. According to the European Stabiliser producers most organotin stabilisers have already been successfully REACH registered. More chemical and use information is also available on this site.
Low-density polyethylene (LDPE) is a thermoplastic made from the monomer ethylene. It was the first grade of polyethylene, produced in 1933 by Imperial Chemical Industries (ICI) using a high pressure process via free radical polymerization. Its manufacture employs the same method today. The EPA estimates 5.7% of LDPE (recycling number 4) is recycled. Despite competition from more modern polymers, LDPE continues to be an important plastic grade.
High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is a polyethylene thermoplastic made from petroleum. It is sometimes called “alkathene” or “polythene” when used for pipes. With a high strength-to-density ratio, HDPE is used in the production of plastic bottles, corrosion-resistant piping, geomembranes, and plastic lumber. HDPE is commonly recycled, and has the number “2” as its resin identification code (formerly known as recycling symbol).
Polycarbonates are a group of thermoplastic polymers containing carbonate groups in their chemical structures. Polycarbonates used in engineering are strong, tough materials, and some grades are optically transparent. They are easily worked, molded, and thermoformed. Because of these properties, polycarbonates find many applications. Polycarbonates do not have a unique Resin identification code (RIC)and are identified as “Other”, 7 on the RIC. Products made from polycarbonate can contain the precursor monomer bisphenol A (BPA). Polycarbonate is also known by a variety of trademarked names, including Lexan, Makrolon, and others.
Polypropylene (PP), also known as polypropene, is a thermoplastic polymer used in a wide variety of applications including packaging and labeling, textiles (e.g., ropes, thermal underwear and carpets), stationery, plastic parts and reusable containers of various types, laboratory equipment, loudspeakers, automotive components, and polymer banknotes. An addition polymer made from the monomer propylene, it is rugged and unusually resistant to many chemical solvents, bases and acids.
Polystyrene (PS) /ˌpɒliˈstaɪriːn/ is a synthetic aromatic polymer made from the monomer styrene. Polystyrene can be solid or foamed. General-purpose polystyrene is clear, hard, and rather brittle. It is an inexpensive resin per unit weight. It is a rather poor barrier to oxygen and water vapor and has a relatively low melting point. Polystyrene is one of the most widely used plastics, the scale of its production being several billion kilograms per year. Polystyrene can be naturally transparent, but can be colored with colorants. Uses include protective packaging (such as packing peanuts and CD and DVD cases), containers (such as “clamshells”), lids, bottles, trays, tumblers, and disposable cutlery.
Thermoplastic elastomers (TPE), sometimes referred to as thermoplastic rubbers, are a class of copolymers or a physical mix of polymers (usually a plastic and a rubber) which consist of materials with both thermoplastic and elastomeric properties. While most elastomers are thermosets, thermoplastics are in contrast relatively easy to use in manufacturing, for example, by injection molding. Thermoplastic elastomers show advantages typical of both rubbery materials and plastic materials. The principal difference between thermoset elastomers and thermoplastic elastomers is the type of cross-linking bond in their structures. In fact, crosslinking is a critical structural factor which imparts high elastic properties.
Acrylonitrile butadiene styrene (ABS) (chemical formula (C8H8)x·(C4H6)y·(C3H3N)z) is a common thermoplastic polymer. Its glass transition temperature is approximately 105 °C (221 °F). ABS is amorphous and therefore has no true melting point.
ABS is a terpolymer made by polymerizing styrene and acrylonitrile in the presence of polybutadiene. The proportions can vary from 15 to 35% acrylonitrile, 5 to 30% butadiene and 40 to 60% styrene. The result is a long chain of polybutadiene criss-crossed with shorter chains of poly(styrene-co-acrylonitrile). The nitrile groups from neighboring chains, being polar, attract each other and bind the chains together, making ABS stronger than pure polystyrene. The styrene gives the plastic a shiny, impervious surface. The polybutadiene, a rubbery substance, provides toughness even at low temperatures. For the majority of applications, ABS can be used between −20 and 80 °C (−4 and 176 °F) as its mechanical properties vary with temperature. The properties are created by rubber toughening, where fine particles of elastomer are distributed throughout the rigid matrix