Rubber Extrusions

Nufox Rubber is a rubber extrusions manufacturer based in Manchester, UK, supplying custom extrusions worldwide. We have over 30 years of expertise in producing intricate rubber extrusions, including complex shapes with internal bridge work to match our customers' precise needs. We offer custom extrusion die cutting to fit any application as well as a wide choice of standard dies.

Our team creates custom rubber extrusions in-house for each client in a process that varies widely to meet precise needs and niche applications. We take pride in representing multiple industries and possess a deep understanding of their unique requirements through an approach that focuses on creative problem-solving that goes beyond routine solutions.

Our expertise includes creating extruded rubber seals, trims, and gaskets for windows and doors that can be used in rail, coach, automotive, or construction industries and more complex bespoke rubber profiles suitable for marine and defence applications.

We design and supply all sizes of rubber extrusion profiles, such as round, square, rectangular, D-section, U-channel, L-extrusions, P seals, square-U, T-profiles, tube sections, angle extrusions, and many more, with the capability to create virtually any custom profile. We can produce flexible rubber tubing, rubber cords such as those used in O-rings, shock-absorbing rubber buffers, and tadpole seals for high-temperature sealing.

Through our highly bespoke service, we work with a range of rubber compounds to deliver the optimal product. Need a flame retardant or conductive part? Talk to us about solid or sponge profiles in natural rubber, PVC, neoprene, EPDM, nitrile, TPE, and many other elastomers.

Silicone is a popular choice among our customers for its durability, hygiene, and temperature resilience. We manufacture solid and sponge silicone rubber extrusions, such as tubing and inflatable seals—always to the high-spec demands of bespoke projects. Scroll down to see more materials we work with.

Our rubber extrusion process is highly controlled to ensure we meet your application requirements. Bespoke rubber extrusion begins with precise die cutting, where we create a custom extrusion die that will determine the cross-section of your rubber extrusion. This is what we call the rubber profile, and its uniquely shaped die is at the core of creating this bespoke rubber extrusion.

We determine the optimal rubber compound to create your rubber extrusions and heat it to a thick, sticky consistency between a solid and a liquid. This viscoelasticity allows the rubber to flow smoothly and retain its structural integrity whilst passing through the die. As it passes through the die, the rubber extrusion is cured, a process called vulcanisation, which improves elasticity, resilience, and heat resistance by cross-linking the polymers within the rubber. For consistent results, continuous vulcanisation continuously cures the rubber extrusion as it moves through the die. This enables us to create extrusions of virtually any length and optimises production speed for more efficient end-product delivery.

In a process known as scarfing, uncured rubber or a solvent-based adhesive is injected into a tool that holds each end to join two rubber extrusions together. The rubber is then cured to create a strong joint or corner. This is something we do when creating automotive window and door seals that require a continuous loop of rubber to ensure a completely airtight fit.

Punching, drilling, notching, and cutting can be arranged post- or in-production to create a complex end product that meets your exact needs.

In cases where two different compounds need to be used, we employ co-extrusion techniques to combine different characteristics, such as hard-wearing outer layers and flexible cores, in one extrusion. Complex designs may also incorporate injection and transfer moulding to form detailed components.

Nufox Rubber offers a collaborative design service for rubber extrusions, fabricating bespoke-made profiles in your chosen or our recommended compound. We can produce various custom rubber extrusions, from tight-tolerance inflatable seals to buffers and rubber fenders. We can even reverse-engineer them from small samples of used profiles.

We have designed many dies for many solutions, consistently producing a smooth extrusion with the desired product dimensions. Although most of our dies are bespoke to each project, we can offer stock rubber tubes and cords up to 70mm in diameter. Every product we produce is rigorously inspected to meet quality standards and match industry requirements.

Custom rubber extrusion offers you more control over:

• Material selection for tailored performance

• Durometer (hardness)

• Profile shape

• Dimensions

• Colour

• Coatings and finishes

• Performance details (e.g. dual-durometer designs or closed-cell/open-cell foam)

Our commitment to quality is reflected in our ongoing investment in production lines and continuous improvement policies. We follow best manufacturing practices to ensure that our customers receive only the highest quality products.