Custom Silicone Extrusion Solutions
When one of our existing silicone profiles, from our library of over 10,000 dies, is not right for your application, we can help you develop a custom silicone extrusion that is manufactured around your exact requirements.
Advanced Materials is a UK manufacturer of bespoke silicone rubber extrusions, supporting engineers, buyers and production teams with practical design advice, in-house tooling and reliable manufacturing. With over 30 years of silicone extrusion manufacturing experience, we work with customers from early concept through to repeat production.
Whether you have a technical drawing, a sample, a worn seal, a sketch or simply an application problem to solve, our team can help turn your requirement into a manufacturable silicone profile.
Bespoke Silicone Extrusions Designed Around Your Requirements
Not every sealing, insulation or protection challenge can be solved with an off-the-shelf product.
A custom silicone extrusion allows you to specify the shape, size, material grade, colour, hardness and performance requirements needed for your application. This can help improve fit, sealing performance, durability and ease of installation.
We manufacture made-to-specification silicone extrusions for a wide range of industrial and regulated applications, including:
- Seals and gaskets
- Tubing and cord
- Edge trims and protective profiles
- Sponge and solid silicone profiles
- Joined rings and frames
- Custom glazing, enclosure and equipment seals
- High-temperature and flame-retardant profiles
- Food-grade and specialist material extrusions
Our role is not only to make the profile but to help you develop a practical, repeatable and cost-effective manufacturing solution.
Custom Silicone Extrusion Manufacturing Capabilities
Advanced Materials combines technical extrusion knowledge with in-house tooling, production and quality control. This gives customers more control over lead times, profile development and repeatability.
Custom Profiles and Made-to-Specification Extrusions
We can manufacture custom silicone profiles from drawings, samples or application details.
Customers often come to us when an existing seal is no longer available, a current profile is not performing as required, or a new product needs a dedicated silicone component. We can review your design and advise on manufacturability before tooling begins.
This helps reduce avoidable tooling changes and the risk of dimensional instability or performance issues later in production.
Material, Colour and Shore Hardness Options
Material selection has a direct impact on performance and manufacturability.
We can advise on silicone grades for temperature resistance, flexibility, sealing performance, regulatory requirements and application environment. Options include solid silicone, sponge silicone, food-grade materials, flame-retardant grades, high-temperature grades, colour matching and self-adhesive backing where suitable.
Shore hardness is also an important design consideration. Harder materials are generally more stable during extrusion, while softer grades can be more difficult to control, especially in hollow or thin-wall profiles. Our technical team can advise on the best balance between flexibility, sealing performance and production stability.
Low-Volume to Full Production Runs
We support both prototype silicone extrusions and repeat production requirements.
For new projects, we can produce first-off samples for approval before moving into full production. For established profiles, our in-house records, retained production samples and tooling library support consistent repeat manufacture.
This is particularly useful for OEMs, resellers and manufacturers who need reliable supply over the long term.
From Concept to Production
Custom silicone extrusion is a development process. The aim is not just to create a tool, but to produce a stable profile that can be manufactured consistently.
Technical Design Support
We start by reviewing your requirements. This may include a drawing, CAD file, sketch, physical sample or description of the application.
At this stage, we can advise on:
- Profile geometry
- Wall thickness
- Hollow sections
- Material grade
- Shore hardness
- Tolerances
- Cost-effective design adjustments
- Production and application considerations
This early input can help improve performance and reduce unnecessary tooling complexity.
Prototype and Sample Development
For many custom silicone extrusion projects, a first-off sample is produced for approval before production begins.
For simple geometries, an extrusion tool and first-off sample can often be manufactured in as little as two weeks. Timescales depend on profile size, complexity, material grade and development requirements.
Samples allow you to check fit, function and dimensions before committing to a production run.
Tooling and Profile Optimisation
Each unique silicone profile requires its own extrusion die unless a suitable existing tool is already available.
At Advanced Materials, extrusion tooling is designed and manufactured in-house by our dedicated toolmakers. This gives us greater control over quality, lead times and profile development.
Silicone tooling is not simply cut to match a drawing. The die must be engineered to account for how silicone flows, swells and behaves during extrusion. Hollow sections, uneven wall thickness, soft materials and larger cross-sections can all increase tooling complexity.
Our in-house tooling capability allows us to make practical adjustments during development, improving dimensional stability and repeatability.
Manufacture and Quality Control
Once approved, production is carried out in-house.
We manufacture silicone rubber extrusions to ISO 3302 Class E1 tolerances as standard unless otherwise stated. Quality production samples are retained for traceability, and certificates of conformity can be supplied with goods, including batch number and cure date information.
We also support customers with documentation such as dimensional reports, test reports and other paperwork where required.
Extensive Existing Tooling Available
Alongside bespoke tooling, Advanced Materials has a large library of more than 10,000 existing extrusion dies.
In some cases, an existing tool may already be suitable for your requirement, helping reduce development time and tooling cost. Where an existing die is not suitable, we can manufacture a new tool in-house.
This tooling library is a useful starting point, but our core strength is custom silicone extrusion development. We focus on finding the right manufacturing route for the profile, not forcing an application to fit an unsuitable existing shape.
Custom Silicone Solutions for Specialist Applications
We supply custom silicone extrusions into a wide range of sectors where reliability, compliance and repeatability matter.
Medical and Healthcare
We manufacture silicone components for medical, healthcare and pharmaceutical equipment applications where material selection, cleanliness, traceability and documentation are important.
Food and Drink Manufacturing
Food-grade silicone extrusions can be used for sealing, protection and processing equipment applications. We can advise on suitable materials and documentation requirements for food production environments.
Electronics and Industrial Applications
Silicone rubber is widely used for insulation, protection, enclosure sealing and vibration reduction. We can develop custom profiles for equipment, machinery, lighting, panels and industrial assemblies.
Automotive, Aerospace and Engineering Applications
For demanding transport and rail, aerospace and engineering applications, we can support projects requiring high-temperature performance, flame-retardant materials, repeatable quality and reliable long-term supply.
Why Work With Advanced Materials?
Choosing a custom silicone extrusion supplier is not only about price per metre. It is about reducing risk across the full project.
We work with engineers, procurement teams, OEMs, manufacturers, distributors and resellers who need dependable silicone components and clear technical support.
With Advanced Materials you have access to:
- Over 30 years of silicone extrusion experience
- UK-based manufacturing in Littlehampton, West Sussex
- In-house tooling design and manufacture
- Two dedicated in-house toolmakers
- Custom profile development and technical advice
- Prototype-to-production support
- ISO 9001 and ISO 14001 certified processes
- ISO 3302 Class E1 tolerances as standard
- Full material traceability and retained production samples
- Certificates of conformity supplied free of charge
- Responsive quotations, often within two hours for custom profiles
Custom Silicone Solutions for Specialist Applications
We supply custom silicone extrusions into a wide range of sectors where reliability, compliance and repeatability matter.
Medical and Healthcare
We manufacture silicone components for medical, healthcare and pharmaceutical equipment applications where material selection, cleanliness, traceability and documentation are important.
Questions About Silicone Extrusion Tooling?
Advanced Materials’ technical team and dedicated in-house tooling experts are available to help customers understand how tooling works, what affects cost and complexity, and how profile design influences manufacturability.
They can explain why every unique extrusion profile needs a dedicated die, how in-house tooling supports lead time and quality control, and why factors such as wall thickness, hollows, cross-sectional area and Shore hardness matter during development.
If you are planning a custom silicone extrusion project, we recommend speaking to one of our experts before finalising your design.
Discuss Your Custom Silicone Extrusion Requirements
If you need a bespoke silicone extrusion, we can help you assess the most practical route from design to manufacture.
Send us a drawing, sketch, sample or application details and our technical team will review your requirements.
Call 01903 713566 or email sales@amsilicones.co.uk to discuss your custom silicone extrusion and request a quotation.