A die trial run is the last cheap moment in a custom extrusion project. Once the first article is approved, the die goes into volume production and every deviation becomes scrap. Treating extrusion die trial and first article approval as a formal gate is what keeps a profile order on schedule.
What the Die Trial Run Is Meant to Prove
The trial run answers three questions before tooling is committed to volume. Does the die fill the profile evenly, or do corners and thin webs starve? Does the profile leave the press straight and free of twist? And does the surface hold up without pickup or die lines? Run the trial at production press settings and production billet temperature, because ideal conditions prove nothing about the real process.
Dimensional First Article Inspection
Measure the first article against the drawing, not a nominal table. The critical checks are wall thickness at the thinnest point, overall width and height, twist over the full length, straightness, and cut length on the first finished parts. Confirm temper and mechanical properties against the certified mill report.
Cross-Section and Wall Thickness Check
A cut section tells you more than a drawing can. Cut samples from both ends and the middle of the trial length and compare their geometry. Look for wall thickness drift, unequal legs, collapsed corners and internal voids in hollow sections. Agree which features are functional and which are cosmetic before you sign.
Surface Finish and Anodizing Validation
Finish is judged on the trial sample, never on a photograph. Inspect for die lines, streaks and colour variation along the length. If the profile will be anodised, have the trial piece anodised to the specified thickness and seal class, then verify thickness and colour against the approved master. For outdoor profiles, a neutral salt spray test to ASTM B117 belongs in first article approval.
Signing Off and Releasing Mass Production
A clean sign-off is a document, not a conversation. The approval record should carry the drawing revision, the alloy and temper, the finishing specification, the measured values of the critical dimensions and the agreed sampling plan for the production run. Keep the approved first article on file with the die number.
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