Extrusion tooling solutions, from first sketch to final profile.
SOLUTION 1
Extrusion Tool Design
The right geometry from the start
Designing an extrusion tool is a discipline that goes far beyond CAD. It requires intimate knowledge of polymer flow behaviour, material characteristics, processing conditions and end-product requirements. After 30+ years of designing extrusion tools for WPC decking, window profiles, roller shutters and technical composite applications, we've built up a design methodology that delivers.
What this includes:
Product design consultation, translating your profile concept into an extrudable geometry
Full die design using state-of-the-art CAD systems
Fully documented, simulation-validated designs, ready for production
Advice on raw material selection and sustainable alternatives, including recycled content
Design for manufacturability and long-term performance
Ideal for:
New profile development (WPC decking, window frames, roller shutters, cladding, fencing), compound changes, optimising an existing die design or replacing an undocumented legacy tool.
Precision extrusion tools.
Engineered to perform.
Precision extrusion tools. Engineered to perform.
SOLUTION 2
Flow & Cool Simulation
Validate before you manufacture
Running blind on a new extrusion tool is expensive. A poorly balanced die can mean weeks of process adjustment, excessive scrap and frustrated operators. Beotool's flow and cool simulation service takes the guesswork out, we model your material's behaviour in the die geometry before a single part is machined.
What this includes:
Computational fluid dynamics (CFD) flow simulation specific to your compound
Cooling simulation to optimise calibration and downstream equipment
Data-driven geometry optimisation: correction of flow imbalances before machining begins
Detailed simulation reports for internal documentation and compliance
Simulation of third-party compounds on existing Beotool designs
The result:
Faster start-up. Less scrap. More confidence in the tool before it reaches your production floor.
SOLUTION 3
In-House Tool Development
We build what we design and we stand behind it
Design and manufacturing are two sides of the same coin. At Beotool and Pesendorfer, design intent is never lost in translation between engineering and the workshop. Our specialised tooling team and trusted manufacturing partners give us end-to-end control over quality.
What this includes:
Full in-house tool manufacturing capability
WPC extrusion dies, modular layout compatible with Beologic and third-party compounds
Die systems for window profiles and roller shutters
Die systems for technical and composite profiles, custom or standardised
Calibration and cooling tank systems, standardised for quick mounting and cost-efficient storage
Granulation heads
On-site installation and commissioning support
Ready-to-run:
Beotool tools are designed to run from day one. We can install and commission the first industrial trial runs at your facility; including process parameter documentation.
SOLUTION 4
Maintenance & Refurbishment
Protect your tooling investment
WPC and composite compounds are abrasive. Over time, even the best-designed die will show wear and wear means quality drift, increased scrap and rising energy consumption. Regular maintenance isn't a cost; it's the most efficient investment you can make in your production line.
What this includes:
Periodic inspection and wear assessment
Full refurbishment, restoring your tool to original specification
Geometry modification, solving chronic processing issues
Technology upgrades, adding high-performance cooling to older tool systems
3D geometry documentation (reverse engineering) for undocumented tools
Service for both Beotool and non-Beotool equipment
Note on non-Beotool tools:
We service and refurbish tools from any manufacturer. Undocumented tools are reverse engineered using high-precision 3D measurement before work begins.
SOLUTION 5
Laboratory & Research Tooling
From lab to line, with the right tools
Not every extrusion challenge starts on the production floor. New compound development, academic research and operator training all require access to properly designed laboratory-scale tooling. Beolabs — Beotool's laboratory tooling range — bridges the gap between lab extruder and full industrial line.
What this includes:
Plug-and-play tool solutions for standard material and profile tests
Adaptation kits for fitting lab extruders to semi-industrial applications
Downsized production tooling, same geometry, lab scale
Standardised clamping and mounting solutions
Optimised online rheometry tools
Customised solutions for specific research or testing requirements
Ideal for:
Universities, research institutes, R&D departments and training centres working with WPC, composite or technical polymer compounds.
SOLUTION 6
Engineering Know-How & Support
Your process problem is our problem too
Sometimes you don't need a new tool, you need an expert eye on your existing line. Beotool's engineering support service puts our knowledge at your disposal: from process troubleshooting and operator training to material selection and full product development support.
What this includes:
Product development support, from concept to compliant profile
Material selection and compound development guidance
Process selection and development for new extrusion applications
Root cause analysis for chronic production issues
Operator and engineering training
Testing, compliance support and process documentation
Available to all extruders:
You don't need to use Beologic compounds to benefit from Beotool's support. Our know-how is available to any extruder working with WPC, composite or technical profiles.
LET’S GET STARTED
Not sure which solution fits your situation?
Tell us what you're working on and we'll point you in the right direction. No sales pitch. Just honest engineering advice.