01Perceive
Sense the billet, the profile, the temper
Fused line-scan and RGB vision, thermal imaging, laser gauging and press PLC telemetry describe the push as it happens — dimensions, wall thickness, straightness, surface, exit temperature.
Physical AI for aluminium & polymer extrusion
The extrusion plant,running itself.
Extruon is the autonomous operations layer for extrusion manufacturing — autonomous billet heating and press control, AI profile-dimension and surface-defect vision, die-flow optimisation, quench, stretch and aging control, robotic handling, and a press-and-die twin that hits target profile and yield before the push.
Deployed at the plant edge · Works with your press PLC, furnace, gauge, quench, saw, aging oven and MES.
Built alongside extruders serving construction, EV, solar and industrial markets
NORDHAUS ALUVantera ProfilesSolFrame SystemsKestrel ExtrusionsRhein LeichtbauAurora Billet Co.
Design-partner names are illustrative pending public reference approval. [PLACEHOLDER]
The problem
Extrusion is stilla black art.
A preheated billet is pushed through a hardened steel die at hundreds of degrees, where metal flows and welds around the die ports to form a precise cross-section. Billet taper, ram speed, container and die temperature, and exit temperature all interact nonlinearly.
- Push a touch too hot or too fast and the profile tears, blisters or picks up die lines.
- Too cold or too slow and it comes out under-strength or off dimension.
- The die itself behaves unpredictably, so plants still endure slow, expensive die trials — scrapping metal and press time to correct twist, bow and flow imbalance.
- After the press, quench rate and stretch-straightening set temper and flatness, and aging ovens develop T5 and T6 properties. Each is another chance to miss spec.
- Press recovery, butt and offcut scrap, and oven energy dominate cost under thin margins and decarbonisation pressure.
- Real-time dimensions
Spot gauging between pushes, not continuous truth. - Surface quality
Die lines and pickup found at packing, not at the die. - Twist and bow
Corrected at the stretcher, if it can be corrected at all. - Temper
Confirmed days later in the lab, after the oven ran. - Recovery and energy
Reconciled monthly, long after the metal is gone.
The push, instrumented
Watch one billetbecome a profile.
Scroll to follow the push: the ram advances, the billet upsets and flows through the die, and the profile emerges on the runout — with Extruon sensing exit temperature, wall thickness and surface the whole way.
Illustrative schematic of an instrumented press: ram, container, die and runout with press-exit sensing. Values shown are representative of a 6063 architectural profile.
How Extruon works
Perceive. Plan. Push.Prove. Learn.
One closed loop runs at the plant edge on every billet. Nothing is advisory-only unless you want it to be — and nothing acts outside an envelope your engineers signed.
02Plan
Set the taper, the speed, the die, the quench
The agents plan billet-heating taper, ram speed, pressure and temperature, die-flow correction, quench rate, stretch, cut length and aging recipe as one coupled decision, not five isolated setpoints.
03Act
Run with adaptive control at the press
Approved moves write back into the press PLC, the furnace and the quench inside bounded action envelopes, with rollback and alarm interlocks wired to the same fail-safe stop your line already trusts.
04Prove
Predict defects and recovery before they cost metal
The loop predicts off-spec dimensions, surface defects, twist and temper misses, and flags die-trial risk early enough to change the push instead of scrapping it.
05Learn
Every correction trains the plant
Engineer approvals and corrections are logged to an immutable, assurance-grade audit trail and fed back into training — so the site's craft compounds instead of retiring.
Seven agents, one orchestrator
The plant runs as a crewof specialised agents.
Each agent owns a physical stage of the line, senses it directly, and acts inside an approved envelope. A plant orchestrator arbitrates between them so nobody optimises recovery at the expense of temper.
Heat-and-press agent
Controls billet temperature taper, ram speed, breakthrough pressure, container and die temperature, and exit temperature to keep metal flow balanced and the profile on dimension.
Profile-and-defect agent
Senses and predicts cross-section dimensions, wall thickness, straightness and surface defects — die lines, pickup, scoring, blisters — from fused vision and laser gauge.
Die-and-flow agent
Optimises die temperature, correction and flow balance to cut die trials and the twist and bow that send profiles back to the stretcher.
Quench-and-stretch agent
Controls press-quench cooling rate and stretch-straightening so temper and flatness land inside spec on the first pass.
Cut-and-age agent
Controls cut-to-length, batching and aging ovens to reach T5 and T6 mechanical properties without over-soaking the oven.
Robot-and-handling agent
Drives robotic pulling, stacking, racking and packing of long, hot, delicate profiles — the handling nobody wants to staff at 3am.
Yield-and-throughput agent
Optimises press recovery, scrap, butt and offcut loss, and energy per tonne across the whole line rather than one station at a time.
Extrusion-knowledge agent
Answers metallurgy and die-design questions with citations into your die books, profile drawings, press recipes and alloy specs.
Press-and-die digital twin
Simulates billet heating, metal flow through the die, quench and profile properties — hitting the target profile and yield before the push, not after the scrap.
Measured on the press
The numbers a plant directoractually gets paid on.
Every Extruon engagement starts with a baseline and ends with an audited delta. These are the target bands we underwrite in a paid pilot.
+4.2 pts
Press recovery uplift, saleable vs charged metal
−38%
Surface-defect and dimensional rejects
−61%
Die-trial pushes before a die is signed off
−12%
kWh per tonne across heating, quench and aging
Target outcome bands modelled from design-partner baselines. [ASPIRATIONAL — to be replaced with audited pilot results.]
The console
One screen for the press,the profile and the money.
Press and process engineers approve, correct and override from a review console. Every correction trains the models — which is how the site's craft stops walking out the door at retirement.
87.9%Press recovery (shift)
508 °CExit temperature
±0.06 mmWall deviation
0.9%Reject rate
- Ram speed −4% · blister risk at breakthrough
- Billet taper adjusted +12 °C front-to-back
- Die 44-118 flow imbalance flagged · trial avoided
- Quench rate held for T6 on rack 19
- Aging batch 7 consolidated · 340 kWh saved
Representative console view. Data shown is illustrative of a single shift on one press.
Why nobody else closes the loop
Gauges measure.Simulators guess.Extruon acts.
Incumbents sell a press-control system, or an in-line gauge, or a furnace controller, or a flow simulator, or an aging controller. None unify them into one plant-edge platform that acts on the process and compounds the data.
Closed perceive–decide–act, at the edge
Extruon does not stop at a setpoint or a measurement. It writes back into heating, press, quench and aging inside approved envelopes, then proves the result on the same push.
The craft, encoded
Every supervised correction from a press operator or die engineer becomes training data. The scarce craft compounds instead of retiring.
100%
of approvals and corrections logged and reused
Rare faults travel
A die-line signature learned on one plant's 6063 architectural family transfers — privacy and IP preserving — to every extruder running similar alloys and profiles.
Hit profile and yield in simulation first
The press-and-die twin simulates billet heating, metal flow, quench and profile properties, so a new die enters the press with corrections already applied rather than earning them through trials.
Who it is for
Three people have to say yes.We answer all three.
The plant director is the economic buyer. Press and process engineers and quality and metallurgy managers are the champions. IT, OT, quality and security approve.
Recovery, throughput, scrap, energy — measured
You own press recovery, throughput, scrap and energy, and you cannot hire your way out of a press-operator shortage. Extruon lands on one press with a hard success metric and an audited baseline.
- Hard ROI proven in a paid pilot before you standardise
- Recovery, scrap, butt loss and kWh per tonne on one dashboard
- Expansion press by press, module by module, site by site
- No dependency on hiring scarce veteran operators
The press stops fighting you
You own billet heating, the press, die performance and profile quality. Extruon runs adaptive speed and exit-temperature control and escalates only the exceptions worth your attention.
- Autonomous ram-speed and exit-temperature control inside your envelopes
- Die-flow imbalance flagged before the trial, not after
- Real-time dimensions, straightness and surface at the press exit
- Your corrections train the model — the system learns your plant
Traceable temper and surface, every rack
You own dimensions, surface, temper and anodising readiness. Extruon predicts temper misses and surface defects and holds an immutable quality audit trail per rack.
- EN 755 and ASTM B221 dimensional and temper traceability
- Surface-defect classification: die lines, pickup, scoring, blisters
- Quench and aging control tied to measured mechanical properties
- Citations back to your die books, drawings and alloy specs
Assurance-grade by default
Trust is the gateto autonomy.
Extruon never asks for control it has not earned. Shadow mode proves accuracy against your operators and gauges; advisory mode proves ROI; bounded autonomy only follows once the gates are met.
Per-tenant everything
Data, models, retrieval indexes and memory are scoped per tenant and per entity. On-prem deployment is available for sensitive producers.
Your die geometry stays yours
Die designs, customer drawings and recipes never leave your boundary. Fleet learning shares defect signatures and process priors, never geometry.
Immutable action log
Every perception, recommendation, approval and setpoint write is recorded with its evidence, ready for quality and customer audits.
SSO, RBAC, encryption
SSO and role-based access, encryption in transit and at rest, SOC 2 programme in progress, and fail-safe interlocks on every write path.
From the floor
What changesin the first quarter.
The first thing that changed was the argument. We stopped debating whether the die or the billet caused the twist, because the system showed us both on the same push.
We used to burn three pushes proving out a new die. Getting that down is press time we sell instead of scrap we melt.
Recovery is the number my board reads. An audited baseline and an audited delta was the only proposal that survived the capital committee.
Design-partner quotes are illustrative of the target outcome. [PLACEHOLDER — to be replaced with named references at GA.]
The finale
Every push,perfectly profiled.
Start with one press and one workflow. We baseline your recovery, scrap and energy, run in shadow, then earn every increment of autonomy against a number you choose.
Land on one press. Expand press by press, module by module, site by site.