When more than tubing is needed, Zeus offers the capability to create custom profile extrusions. Since 1966, we have been empowering our partners by extruding complex shapes and geometries that can house various wires, cables, optical fibers, and more. Zeus fabricates our dies in-house, allowing us to quickly take your concept and deliver a customized profile extrusion rapidly. You design, we deliver.
In addition to tight-tolerance tubing, monofilament, and various other extruded products, Zeus excels in producing tight-tolerance custom profile extrusions in a variety of resins, including PTFE, PEEK, FEP, PFA, PVDF, ETFE, ECTFE, and Nylon. From standard products such as guide rail covers to ultra-precise extruded profiles for minimally invasive surgical devices, we have developed technology to bring unique extruded profiles from concept to reality.
Drawing on decades of experience and a broad selection of high-performance resins, Zeus is the business partner of choice for developing the solutions you require. Working with our customers early in their project design stage, Zeus polymer and extrusion experts offer guidance for materials, configurations, and optimization. Our world-class analytical labs and polymer chemists test, analyze, and propose solutions to maximize the performance of your extruded profile. Bring us your CAD drawing with dimensions and tolerances, or just give us an indication of your ideas, and we will do the rest!
If you do not see your preferred resin listed here for a custom profile, contact us or call toll-free in the US 1-800-526-3842 or +1-803-268-9500 internationally to see how we can help you.
Engineered Surface Tubing – Our team developed a process to increase lubricity and decrease drag force through the extrusion of micro-structured channels, or “reeds,” along the tube. These reeds lower the coefficient of friction by reducing surface area contact of the outside diameter of the tube with its environment. Our engineered surface process enhances the lubricity on either the inside diameter (ID), outside diameter (OD), or both without additives or fillers.
Guide Rail Covers – Our “C” shape guide rail covers reduce rail wear and extend the life of conveyor systems. These guide rail covers are ideal for packing and processing soft drinks, food, chemicals, and many other mass-produced items.
Splines – These custom extrusions allow cables, wires, and fiber optics to be centered and insulated. Additional areas can be incorporated into the extrusion that reduce impacts from vibration or shock to the wiring. Splines can be extruded in a variety of performance materials such as PTFE, FEP, and PEEK, all of which provide excellent dielectric strength. Spline shapes can be manufactured as stand-alone extrusions or extruded over wiring.
Chemical Resistance – The materials our custom profiles are made from are highly resistant to a broad spectrum of commonly encountered chemicals. At Zeus, we can help you select the best polymer choice for your application to give your product superior chemical resistance. We have resins that are chemically inert to almost all common solvents, whether acids, bases, or hydrocarbons.
Heat Resistance – Depending on your resin choice, your custom profile tubing can have a working temperature of up to 500 °F (260 °C).
Lubricity – By minimizing the contact area between the outer tubing surface profile and its surroundings, these profiled tubes increase lubricity beyond the already low coefficient of friction of the polymer from which the tubing is made.
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