How to Extrude LDPE on Copper

Low-density polyethylene, or LDPE, is a petroleum-based thermoplastic originally produced in 1933 by Imperial Chemical Industries. It is most commonly used in manufacturing plastic bottles and plastic bags. However, it is also used to make sheathing on copper wires via a process known as extrusion. Extrusion is the process used to create objects of a fixed cross-sectional profile. In this case, copper wire rolled on giant spools is pushed and drawn through a heavy industrial machine known as a continuous line extrusion machine as the sheathing is then molded to the wire. This work is only performed in copper and aluminum extrusion plants. Continuous copper extrusion machines are not designed to be operated in domestic or home settings.

Safety gloves
Protective glasses
Continuous line extrusion machine

Instructions

- 1
  Place safety gloves and goggles on first.
- 2
  Pull the end of the copper wiring to be extruded, unrolling it from its giant spool.
- 3
  Pull and feed the copper wire through the series of straightening pulleys.
- 4
  Feed the first foot of the end of the copper from the spool into the front end of the copper extrusion machine. Turn the feed crank on the side of the machine to set and lock the copper cable into place.
- 5
  Enter the gauge and size of the copper wiring to be extruded via the keyboard mounted on the machine's control panel. Depending on the model of the continuous extrusion machine, the total amount of footage to be extruded and the heating temperature may also need to be entered by hand. For example, if 30,000 feet of copper needs to be extruded at a temperature range between 1,200 and 2,000 degrees F (which is the hot extrusion temperature range for copper), input 30,000 feet for total footage and 1,200 to 2,000 degrees for temperature.
- 6
  Press the start controller on the extrusion machine's control panel. The machine should activate and pull the copper wire through the machine for extrusion process.

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