Extruder Tips & Dies Manufacturers in India

Sai Extrumech manufactures precision extruder tips and dies in India for wire and cable extrusion lines. The tip and die are the two parts that actually form the insulation around a conductor, and their accuracy decides your wall thickness, concentricity and surface finish. We machine tips and dies for our own crossheads and for any make of extruder — matched to your conductor size, compound and line speed.

What Are Tips and Dies?

Inside a crosshead, the tip (also called the guider or core tube) supports the moving conductor and sets the inner diameter of the coating. The die sits around it and sets the outer diameter. The gap between the two — and how the melt is drawn down through it — controls the insulation wall thickness. If the tip and die are not concentric or the geometry is wrong, you get eccentric insulation, thickness variation, poor surface finish and rejected cable.

Tooling Types We Manufacture

Pressure Tooling

The melt meets the conductor inside the die, under pressure, giving tight adhesion to the conductor. Used where the insulation must bond firmly — typical for primary insulation on building wire and power cable.

Tubing Tooling

The melt leaves the die as a tube and is drawn down onto the conductor outside the die. This gives a looser fit and is used for sheathing, jacketing and applications where the coating should strip cleanly.

Semi-Tubing Tooling

A balance between the two, used where you need some adhesion but also controlled drawdown. We select the geometry based on your compound and cable specification.

Materials and Sizing

• Hardened tool steel for general PVC, PE and XLPE compounds
• Stainless steel where corrosion resistance is needed
• Tungsten carbide options for abrasive and highly filled compounds that wear standard tooling quickly
• Sized to your conductor range and finished insulation outer diameter
• Drawdown ratio and draw balance calculated for your compound and line speed
• Supplied as matched tip-and-die sets so the pair works together

Tips and Dies for Any Make of Extruder

You do not need to run a Sai Extrumech machine to buy our tooling. We manufacture replacement tips and dies to match tooling from other manufacturers — send us a sample, a drawing, or your machine make and model and we will match it. See our replacement extruder tooling page for how that works.

Why Choose Sai Extrumech

• 25+ years machining extrusion tooling in Faridabad, India
• In-house CNC machining — no third-party sub-assemblies
• Matched tip-and-die sets for conductor sizes across the cable range
• Tooling for our crossheads and for any other make of extruder
• Carbide options for abrasive compounds
• Exports to UAE, UK, South Africa, Bangladesh, Nepal & Sri Lanka

Related Tooling

Tips and dies work inside our precision crossheads. We also supply complete extruder tooling, screws and barrels and spare parts. See the full product range, built by trusted cable extrusion machinery manufacturers.

Cable Standards Referenced in Extrusion Tooling

Insulation and sheathing produced on a cable extrusion line is normally specified against a published standard, and that standard sets the wall thickness and tolerance your tooling has to hold. The specifications most commonly referenced by Indian and export cable producers are:

• IS 694 — PVC insulated cables for working voltages up to and including 1100 V (Bureau of Indian Standards)
• IS 7098 — Cross-linked polyethylene (XLPE) insulated cables (Bureau of Indian Standards)
• IS 1554 — PVC insulated heavy-duty cables (Bureau of Indian Standards)
• IEC 60502 — Power cables with extruded insulation and their accessories (International Electrotechnical Commission)
• ISO 6722 — Road vehicles, 60 V and 600 V single-core cables, used for automotive wire (International Organization for Standardization)

The tolerance band in the applicable standard is what determines the die and tip geometry you need. Tell us the standard your cable is built to along with the conductor size and compound, and we will size the tooling to hold it.

Frequently Asked Questions

What is the difference between a tip and a die?

The tip supports the conductor and sets the inner diameter of the insulation; the die sets the outer diameter. The gap between them, and the drawdown through it, controls the wall thickness.

Do you make tips and dies for other manufacturers’ extruders?

Yes. We manufacture replacement tips and dies for any make of extruder. Send a sample, a drawing, or your machine make and model and we will match the tooling.

Which tooling type do I need — pressure or tubing?

Pressure tooling is used where the insulation must bond tightly to the conductor; tubing tooling is used for sheathing and where the coating should strip cleanly. We recommend the type based on your compound and cable spec.

Can you supply carbide tooling for abrasive compounds?

Yes. Filled and abrasive compounds wear standard steel tooling quickly, so we offer tungsten carbide options for longer life.