Die & Flow
Optimises die temperature, correction and flow balance to cut die trials and the twist and bow they exist to fix. Measured on trials per new die and press hours burned proving out.
Products
Eight modules.One plant orchestrator.
Every module is a deployable product with its own sensors, its own envelopes and its own ROI metric. They compose into whole-plant autonomy — but you never have to buy them that way.
Deploy one module on one press, or the whole loop across the plant.
Module 01
Heat & Press.The push, controlled.
The 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.
- Isothermal extrusion held at the maximum safe speed rather than a conservative fixed recipe.
- Breakthrough pressure managed to avoid blistering and tearing at the start of the push.
- Taper set per billet, per alloy, per die — not per shift.
- Writes back through bounded envelopes with rollback on any alarm.
Ram position, speed and pressure · container and die thermocouples · furnace zone temperatures · billet ID and alloy · exit pyrometer
Ram-speed profile · taper setpoints · container and die temperature · breakthrough ramp
Exit-temperature stability, recovery, speed-limited throughput, tear and blister rate
Module 02
Profile & Defect.The truth at the exit.
The profile-and-defect agent senses and predicts cross-section dimensions, wall thickness, straightness and surface defects from fused vision and laser gauging — continuously, at line speed.
- Die lines, pickup, scoring and blisters classified and attributed to the die and push that produced them.
- Wall-thickness and width deviation tracked against the drawing, not against a sample.
- Twist and bow detected before the stretcher rather than discovered by it.
- Predicts off-spec before it is measurable, so the push can be changed instead of scrapped.
4–8 synchronised line-scan / RGB cameras · thermal imaging · laser profile gauge · press telemetry fusion
Sub-250 ms defect and dimension alerts at 30–120 FPS. [ASPIRATIONAL]
Reject rate, escape rate to packing, dimensional capability, rework hours
Modules in place
Every modulesits on the same push.
Heat and press act before the die. Profile and defect senses after it. Die and flow explains both. Quench, stretch, cut and age finish the job. Yield and throughput keeps score.
Modules share one perception fabric and one orchestrator — so a recovery gain is never bought with a temper miss.
Modules 03–08
The rest of the line,module by module.
Quench & Stretch
Controls press-quench cooling rate and stretch-straightening for temper and flatness. Measured on T5/T6 first-pass yield and flatness rejects.
Cut & Age
Controls cut-to-length nesting, batching and aging-oven recipes to reach mechanical properties without over-soaking. Measured on offcut loss and oven kWh per tonne.
Robot & Handling
Drives robotic pulling, stacking, racking and packing of long, hot, delicate profiles. Measured on handling damage, packing labour and shift coverage.
Yield & Throughput
Optimises press recovery, scrap, butt and offcut loss, and energy across the whole line. Measured on recovery points and cost per tonne.
Press & Die Twin
Simulates heating, metal flow, quench and profile properties to hit target profile and yield before the push. Measured on first-push success on new dies.
What ships with every module
The parts youdo not have to ask for.
Review console for engineers
Approve, correct and override every recommendation. Corrections are the training signal — the console is how your plant's craft gets encoded instead of retiring.
Assurance-grade audit log
Immutable record of every perception, recommendation, approval and write, with the evidence attached.
100%
of agent actions logged
Plant-edge runtime
Runs on site. Degrades safely. Never depends on a live cloud link to keep the press safe.
Connectors to your systems of record
Press PLC, billet-heating furnace, in-line gauge and vision, quench, stretcher, saw, aging oven and MES — read in shadow, write-back enabled per setpoint when you say so.
Module map
Pick the moduleby the metric.
| Module | Primary ROI metric | Typical champion |
|---|---|---|
| Heat & Press | Recovery points, speed-limited throughput | Press / process engineer |
| Profile & Defect | Reject rate, rework hours | Quality / metallurgy manager |
| Die & Flow | Trials per new die, press hours | Die engineering manager |
| Quench & Stretch | T5/T6 first-pass yield, flatness rejects | Quality / metallurgy manager |
| Cut & Age | Offcut loss, oven kWh per tonne | Plant / operations director |
| Robot & Handling | Handling damage, packing labour | Plant / operations director |
| Yield & Throughput | Recovery, cost per tonne | Plant / operations director |
| Press & Die Twin | First-push success on new dies | Die engineering manager |
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
What modulesare measured 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.]
Module by module
Land narrow.Expand relentlessly.
We bought one module for one press because that was the only thing finance would sign. Two quarters later it was three presses and the quench.
The twin is what changed the die conversation. We stopped arguing about whose fault the twist was and started running sweeps.
Handling was the unglamorous one and the easiest sell. Nobody wants to rack hot profiles at 3am.
Design-partner quotes are illustrative of the target outcome. [PLACEHOLDER — to be replaced with named references at GA.]
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.
The finale
One module.One press. One number.
Tell us which metric matters most this year and we will tell you which module to start with — and what the baseline needs to look like.
Land on one press. Expand press by press, module by module, site by site.