What sets a reliable partner in plastic profile extrusion apart is not just production capacity, but above all the way they guide the customer from technical requirements to the finished component, developing a fully custom project. From initial consultation to mass production, at VBN every phase is managed in-house, drawing on technical expertise built up over nearly 70 years of activity.

Project feasibility analysis

The starting point is listening to the customer’s needs. Before starting a project, it is essential to understand the environment in which the profile will be used, the mechanical stresses it will need to withstand, whether it will be exposed to extreme temperatures, chemicals or humidity, whether it must meet specific aesthetic requirements, and whether it needs to integrate with existing components. Every piece of information helps define the scope of the project.
Once the specifications are understood, the technical department begins the feasibility analysis. This step serves to verify that the desired geometry is compatible with the extrusion process. Thicknesses, cavities, angles, fillets and tolerances are carefully studied to ensure manufacturability and performance.
At the same time, material selection takes place. VBN works with a wide range of plastic polymers, each with different mechanical, thermal and chemical properties. The choice of material influences not only the performance of the final product, but also the behavior of the profile during extrusion, its dimensional stability and its long term durability.

From technical drawing to plastic profile engineering

With all the information gathered, the technical department proceeds with the profile design. If the customer already has a drawing or a CAD file, it is reviewed and optimized according to production requirements. If the project starts from scratch, VBN develops the design in-house with an efficiency oriented approach.
Profile engineering takes into account factors that are not immediately visible: material shrinkage during cooling, thickness distribution to prevent deformation, and the optimal positioning of fixing points or connections with other components. Every detail is carefully evaluated to ensure a balance between functionality, quality and cost.

Custom mold design and production

The mold is the element that defines the shape of the profile. It is the die through which the plastic material is extruded. Designing it correctly means virtually anticipating every variable that occurs during extrusion: material flow distribution, potential stagnation zones, internal pressure balance and thermal management. At VBN, this work is carried out in our in-house tooling department, using CNC controlled machines and a team of specialized toolmakers.
Having mold production in the house is a concrete benefit. It means shorter lead times, direct communication between designers and manufacturers, and above all the ability to respond quickly if changes occur. A well designed die ensures dimensional stability, surface quality and repeatability over time.

Prototyping testing before production

Before moving to mass production, VBN includes a prototyping phase where the design is tested. By producing extrusion samples, it is possible to verify profile dimensions, the suitability of the chosen plastic material, tolerances, and both aesthetic and functional properties in line with the design specifications. This phase allows any deviations from requirements to be identified and corrected before they become production issues. The prototype is tested in the laboratory through dimensional measurements, mechanical testing and compliance checks against the required specifications. In complex profiles, prototyping also makes it possible to verify how the different elements integrate with one another and whether any interferences occur.
Only when the sample meets the defined parameters is process validation carried out and production begins.

Mass production of plastic profiles

VBN operates 50 different extrusion lines for plastic processing, enabling the production of extruded parts in any length. Production capacity is designed to handle both large volumes and smaller batches while maintaining consistent quality. The company is also capable of both extrusion and co-extrusion processes, in which different materials are combined and extruded together through the die.
Each production line is continuously monitored: process parameters, extrusion speed, temperatures and dimensional tolerances. In-line operations such as cutting to size, marking, drilling and shaping can be integrated directly into the production cycle, reducing handling times and overall costs. Where necessary, offline operations and assembly complete the profile before delivery.
The certified quality control system ensures full traceability of every batch and compliance of the product with customer requirements.

Discover our custom designed plastic profiles.