At Paul Murphy Plastics, we know that every product design brings unique challenges. Off-the-shelf components often don’t meet specialized requirements, and that’s where custom plastic extrusion steps in. For over 60 years, we’ve partnered with engineers, designers, and manufacturers to deliver tailored plastic profiles that solve real-world problems—efficiently, consistently, and at scale.
Custom plastic extrusion isn’t just about shaping plastic. It’s about engineering precision, improving product functionality, and reducing production inefficiencies. Whether you need high-temperature resistance, a complex cross-sectional shape, or a material blend optimized for durability and flexibility, custom extrusion allows you to achieve exactly what your application demands.
What Is Custom Plastic Extrusion?
Plastic extrusion is a continuous manufacturing process where raw plastic is melted and shaped into a specific profile or form. In custom extrusion, the tooling (or die) is made to match your product’s exact specifications, whether you’re working with tubing, profiles, or complex multi-durometer designs.
The result? Tailor-made parts that meet your performance, dimensional, and aesthetic requirements—down to the millimeter.
You can explore our full offering of plastic extrusion capabilities, including tubing, co-extrusions, hollow profiles, and precision cut-to-length parts.
Key Benefits of Custom Plastic Extrusion
- Design Flexibility
Custom extrusion opens the door to unlimited design possibilities. Whether you need unique cross-sections, variable wall thicknesses, or integrated features like slots, flanges, or snap-fits, we can engineer a solution that aligns perfectly with your application.
We’ve created profiles for everything from medical devices to window insulation systems—each one optimized for its end-use environment.
- Material Versatility
One of the greatest advantages of extrusion is the broad range of thermoplastics available. At Paul Murphy Plastics, we work with PVC, ABS, polyethylene, polyurethane, nylon, and custom compounds to meet specific requirements such as flame resistance, UV stability, and chemical compatibility.
Need help selecting the right resin? Our material experts will guide you toward a solution that balances performance, cost, and manufacturability.
- Cost Efficiency at Scale
Once your tooling is created, the extrusion process becomes highly cost-effective—especially for medium to high-volume runs. Because it’s a continuous operation, plastic extrusion minimizes waste and allows for automation in cutting, drilling, and coiling.
And with our in-house tooling development and maintenance, you’ll avoid the high overhead associated with third-party die design.
- Improved Assembly and Function
Well-designed extruded parts can reduce or eliminate secondary assembly steps. For example, adding a snap-fit feature or integrated gasket can streamline your production process, reduce component count, and improve final product reliability.
In many cases, what starts as a minor profile optimization result in major gains across your supply chain.
- Proven Quality and Repeatability
With Paul Murphy Plastics, quality is engineered into every step. Our extrusion lines are equipped with real-time monitoring and in-line inspection to ensure your profiles meet tight tolerances, every time. And with decades of extrusion experience, we know how to maintain consistency—even across high-volume or long-run production schedules.
Why Work with Paul Murphy Plastics?
We bring more than equipment—we bring partnership, engineering insight, and industry expertise. Our team works directly with your product designers to understand your goals and develop extrusion solutions that exceed expectations.
We support you from concept to production with:
- In-house die design and prototyping
- Precision manufacturing with tight tolerances
- Custom color matching and finishing
- Value-added secondary operations (punching, taping,
printing)
As a trusted leader in plastic extrusion for OEMs across the U.S., we’re ready to help you turn complex requirements into practical, high-performance parts.
