Every manufacturing process has its physical and technical limits. However, by combining different technologies, it is possible to overcome these restrictions and achieve new levels of complexity and efficiency. This is the principle behind composite profiles: the intelligent interaction of two different manufacturing processes allows for the expansion of dimensions, more complex geometries, and the use of multiple steel grades within the same profile.
Advantages of Composite Profiles
Compared to extruded and hot-rolled profiles, composite profiles offer unique benefits that open up new design and production possibilities:
- High design flexibility – complex geometries and custom shapes become feasible.
- Material mix – different steel alloys (carbon steel, high yield grades, ferritic, duplex, or austenitic stainless steels) can be combined in a single profile.
- Increased profile dimensions – larger sections beyond the limits of extrusion machines can be achieved.
- Open and hollow sections – allows for creative and functional designs not possible with standard processes.
With composite profiles, manufacturers can push the boundaries of what is technically possible, creating products that are both stronger and more versatile.
How Composite Profiles Are Made: An Example
Imagine a customer requests a stainless steel profile with the geometry shown in image 1. Manufacturing this piece by hot extrusion alone is not possible due to the dimensional limits of the machinery (image 2). The solution is to produce single components via extrusion and then combine them through laser welding, resulting in the required final profile (image 3).
This hybrid approach combines the strengths of multiple processes, delivering a high-quality and technically feasible product. Watch the video above to see the process in action, or visit our YouTube channel for more case studies.
Requested Profile |
Hot Extrusion |
Hot Extrusion + Laser Welding |
image1 |
image2 |
image3 |
Dimension:400mm x 450mm |
Dimensional limit:max. Ø255 mm |
Composite process:no dimensional limit |
Manufacturer of Composite Profiles: Montanstahl & Partners
The production of composite profiles requires advanced expertise and high-precision processes. Montanstahl, together with Innostahl Engineering GmbH and Hoesch Schwerter Extruded Profiles (HESP), has developed strong know-how in this field, offering customers innovative solutions at competitive prices.
Note: Since July 1, 2021, HSEP has officially joined the Montanstahl Group as Montanstahl GmbH, further strengthening our capabilities in the field of composite profiles.
Composite Profile Tolerance
One of the key aspects when designing and manufacturing composite profiles is the dimensional tolerance. Since these profiles are created by combining different processes such as extrusion and laser welding, the achievable tolerances
differ from those of hot rolled or extruded profiles alone.
Montanstahl applies strict quality control during each production step to ensure that composite profiles meet the required dimensional accuracy. Tolerances depend on factors such as section geometry, thickness, and material grade,
but they are always kept within limits that guarantee safe application in structural and architectural projects.
Thanks to precision laser welding technology and careful process monitoring, we are able to minimize deviations and deliver profiles that are consistent, reliable, and suitable even for demanding engineering applications.
Have a design request in mind? Share it with us and we will help you find the best solution.
