Aluminum and steel impact extrusion is an efficient manufacturing process well suited for the production of cans, tubes, and other similarly shaped metal parts. Impacting creates parts of near-net shape, bringing with it many cost and performance benefits.
The impact extrusion process is one of the fastest ways to get to near-net shape for many parts and components. Our process begins with a lubricated metal slug—also called a blank or a puck—that is placed in a die cavity.
The metal puck is struck with a punch powered by a mechanical or hydraulic press. This forces the metal to flow into a shape or position almost instantly.
The resulting shape of the extruded part depends on what type of impact extrusion is being performed: reverse impacting, forward impacting, or combination impacting. Below are graphics that highlight the key differences and attributes of the three main types.
In reverse impact extrusions, metal flows backward—the opposite direction of the force that is delivered—and around the punch. The resulting part is the same shape of the punch.
In forward impact extrusions, the punch forces the metal through an opening in the die. The punch fits the die cavity so closely that no metal is able to flow backward.
Combination impacting involves both impacting processes. Producing more complex part shapes, combination impacting forces metal through an opening and also backward around the punch.
Steel impact extrusion is often the right manufacturing process when a part needs strength, repeatability, and near-net-shape efficiency without excessive machining waste. The process can be especially valuable for high-volume components where material utilization, part consistency, and production speed all affect total cost.
Thunderbird Metals supports steel impact extrusion projects with in-house engineering, tool and die expertise, finite element analysis, hydraulic and mechanical press capacity, heat-treating support, automated lubrication, and rigorous first- and last-piece inspections.
Steel places higher demands on tooling, equipment, lubrication, and process control than many softer metals. That is why manufacturability review matters early. Thunderbird Metals evaluates part geometry, material behavior, tolerances, production volume, and secondary operations so the steel impact extrusion process is designed around the finished component, not only the initial form.
If you are comparing steel extrusion, impact extrusion, forging, casting, or machining, Thunderbird Metals can help determine whether your part is a good candidate for steel impact extrusion before tooling or production decisions are made.
Yes. Steel can be impact extruded, but it requires the right engineering, tooling, press capacity, lubrication, and process control. Steel creates higher forming stresses than aluminum, so experience with tool design and production setup is important.
Good candidates are usually components that benefit from near-net-shape forming, reduced waste, strong repeatability, and high-volume production. Parts that currently require extensive machining may be worth reviewing for impact extrusion.
Thunderbird Metals combines steel impact extrusion experience with in-house engineering, finite element analysis, tool and die support, robotic integrations, heat-treating support, automated lubrication, and inspection processes built for production quality.
The best next step is a part review. Share the drawing, material, tolerance needs, annual volume, and current manufacturing method so the Thunderbird Metals team can evaluate whether steel impact extrusion can improve cost, quality, or delivery.
