HyperXtrude® introduces a new CAD interface for HyperXtrude solver and takes a giant leap to a direct CAD to solution approach. Meshing and data deck creation is handled automatically in the background with no user intervention. Hence, users can submit the analysis after creating the CAD model.

Today's extrusion companies are forced to produce a higher mix of complex profiles in shorter product development cycles while simultaneously reducing their production costs. HyperXtrude is a simulation environment to meet these needs and increases productivity by analyzing and optimizing extrusion dies, and process conditions.

HyperXtrude is like a virtual press where the user can visualize material flow and temperature inside a die during extrusion, and make necessary changes to ensure balanced flow and eliminate product defects. HyperXtrude helps reducing costly die-trials.

HyperXtrude is widely used in the extrusion industry and since its inception in 1999, its development is driven by the industry and customer needs.

HyperXtrude® 2015 introduces a new CAD interface for HyperXtrude solver and takes a giant leap to a direct CAD to solution approach. This approach automates and hides the meshing and data deck creation, and completely relegates it to the background. Hence, users can submit the analysis after creating the CAD model. In this release, interface for steady state, transient analysis, bearing optimization and tool deflection for metal extrusion is supported.




HyperXtrude offers an analysis tool for virtual testing, validation, correction, and optimization of extrusion die designs.

Minimize die design time and cost

Robust, reliable and efficient computer simulation provides insight and direction before cutting dies and press set-up.


Design Robust Die Assemblies

Accurately predict tooling deflection and stresses due to extrusion loads to optimize die designs.


Visualize and Understand Extrusion Material Flow, Temperatures, Pressures, and Forces

Visualization of complete three dimensional model helps in understanding die behavior for various process conditions.


Minimize Weld Scrap

Calculate transverse weld length to minimize weld scrap.


Reduce Costly and Time Consuming Die Trials

With CAD to solution approach extrusion analysis can be performed easily and with quick turnaround time.


Significantly Reduce the Overall Product Development Cycle Time:

Virtual extrusion simulation will speed up the design optimization and also reduces time consuming die trials.

Experimental validation of a testcase

Die swell prediction

Simulation of a hollow polymer extrusion die

Simulation of a tube extrusion die

Multi-hole polymer extrusion die analysis

Hyperworks Desktop provides side-by-side pre- and post-processing



HyperXtrude is a CAE tool used for virtual testing, validation, correction, optimization of extrusion process and die designs. Using HyperXtrude's broad capability set, engineers can identify design errors before they become costly problems.


Extrusion Specific User Interface:

  • Import die drawings in native CAD data format
  • Process flow based extrusion wizard enables users to analyze dies in a few simple steps
  • The HyperXtrude 2015 provides a CAD interface that can automate and hide the meshing and data displays, relegating them to the background and speeding pre-processing.


Support for All Die Types:

  • Solid, semi-hollow, and hollow profiles
  • Multi-hole dies
  • Co-extrusion of two or more materials
  • Feeder plates and spreader dies (metal extrusion)
  • Direct, Indirect, and conform extrusion processes (metal extrusion)
  • Film and sheet extrusion (polymer extrusion)
  • Spiral dies (polymer extrusion)
  • Extrusions with metal inserts (polymer extrusion)


Virtual Die Trials:

  • Visualize material flowing through the die passages
  • Determine causes for flow imbalance
  • Study responses to design changes
  • Perform ‘what-if’ studies to test innovative die designs


Thermal Management:

  • Determine optimum billet preheat using HX-Process (metal extrusion)
  • Coupled flow and thermal solvers
  • Control exit temperature through use of heating elements and/or cooling pipes in the tool
  • Determine temperature changes in tool between different extrusion cycles


Predict Extrusion Defects:

  • Profile shape prediction
  • Surface defects
  • Metal extrusion:
    • Track surface impurities and prevent them from entering the profile
    • Determine transverse weld length
    • Predict the quality of seam welds in the weld chamber
    • Predict grain size and tensile yield strength of the profile


Tool Deflection Analysis:

  • Coupled flow, thermal, and stress analysis solver
  • Calculate die deflection and mandrel shift during extrusion using OptiStruct
  • Minimize tool deflection to meet product tolerances
  • Identify causes for tool breakage
  • Optimize the shape and size backers and bolsters using Altair OptiStruct


Comprehensive Material Database:

  • HyperXtrude comes with a database of commonly used polymers, alloys for tool and work piece materials
  • Built-in calibration module to fine tune material properties
  • User subroutines enable users to add new material models


Optimize Dies & Production:

  • Bearing length corrections by using built-in optimizations tool in HyperXtrude
  • Optimize the die designs using Altair® HyperStudy® to modify bearing lengths and pocket dimensions (metal extrusion)
  • Calculate optimum process conditions (ram speed, billet preheat, taper) using HX-Process (metal extrusion)



  • Temperate in tool and work piece
  • Velocity and profile shape
  • Tool deflection and stresses
  • Profile grain size, yield strength (metal extrusion)
  • Plotting features: Animations, Vector plots, Contour plots, Cutting planes and X-Y plots