Extrusions & Splice Rubber Professionals

WARCO specializes in custom rubber extrusions, from one-time special orders to high-volume runs. Our extruders can produce custom rubber profiles in a wide variety of sizes and shapes including cable jacketing, O-ring cord, tubing, rubber seals, rubber strips, solid rubber cords, squares, and rectangles. Our experienced sales team can provide product selection and design support, whether you require standard extruded rubber gaskets or custom extruded rubber profiles. With our in-house formulation and mixing capabilities coupled with die design and fabrication on state-of-the-art die-making equipment, we can design a rubber compound to meet your specific requirements for quality and performance while minimizing cost.

23 Black Profiles of Small, Large, and Abnormally Shaped Extruded Tubes

Standard & Custom Extruded Cord Dimensions

Our standard extruded rubber tube, cord, and sleeve dimensions are below.

Wall Sizes

ID/OD Sizes

Sample Profiles

We can also extrude virtually any profile within a range of 1 inch to 6 inches in diameter

Our Specialty Extruded Rubber Products

Select a specialty extruded rubber product below to learn more.

PURE – NSF/ANSI/CAN 61 Certified Extrusions

Close Up of Black Extruded Rubber Cable Jacket with Protected Inner Wires

Neoprene Cable Jacket Tubing to MIL-R-6855 / MIL–PRF–6855

60 Durometer Neoprene Tubing

(Rubber Bumpers)

Rubber Waterstop
(Extruded Rubber)

Our Extruded Rubber Products

Select an extruded rubber product below to learn more.

Neoprene Rubber

Nitrile Rubber

EPDM Rubber

FKM (Viton™) Rubber

Silicone Rubber

Natural Rubber

SBR Rubber

Spec Grade Rubber

Our Extrusion Manufacturing Process

Chemist Operating a Sheet Rubber Thickness Testing MachineThe process begins with our experienced sales representatives assisting you in product development, design, and profile construction. Once the product’s needs, applications, and timeline have been determined, the request is sent to our Research & Development Lab. Our research and development lab team of chemists and engineers will create a custom formulation that will best fit the determined requirements. Our commitment to research and formulation development has kept us at the leading edge of rubber technological innovation. This formulation is then sent to our In House Mixing and undergoes the first Quality Assurance Check.

Batch of Rubber Mixing Cooling TankAll formulas are mixed with our Banbury® machine and thoroughly tested before it is used in manufacturing in order to make sure that we are delivering excellence in quality. After the rubber compound batch has been formulated, mixed, and tested, it is now able to move to our compound and mix stock room to begin the manufacturing process.

 Next, the material is taken to our extrusion department. We offer a multitude of different options when it comes to extrusions including microwave, cold feed with hot air vulcanization, and much more! 

We have three ways to vulcanize our extruded profiles, Autoclave, Hot Air Convection and Microwave. If the extrusion requires separate vulcanization, then our team prepares the material in a way that it will maintain its shape and quality throughout the process.

Stacks and Boxes of Packaged Rubber ProductsOnce the extrusion is cured then it will be subject to a number of different product preparation methods as needed. We offer a number of different services in order to ensure that our customers get the highest quality product available. These services include marking, stenciling, private branding and much more. If needed your extrusion can be spliced with our splicing department, learn more about splicing below.

At this time, our packaging and shipping department prepares the rubber for transport. Each of our products are packed with extreme care and precision in order to ensure that your product is delivered to you in pristine condition. These products are given to our partners within the transportation industry and they deliver directly to wherever your desire.

Custom Profiles are our Specialty

Compounding capabilities include Neoprene, EPDM, Nitrile, Fluorozone® FKM & Viton®, Natural Rubber and Silicone. We also provide custom compounding to meet Military, AMS, SAE, ASTM, NSF, FDA and commercial specifications. View our Specifications.

WARCO’s diverse production equipment & capabilities include:

  • Hot feed extruders, which range in size from 1 IN to 6 IN diameter
  • Advanced microwave extruders are capable of curing continuous lengths of rubber extrusions, resulting in improved processing speeds, curing times, closer tolerances and ensuring a cost-effective, quality part.
  • A 50 FT autoclave produces straight lengths up to 50 FT
  • A unique pole cure system that enables us to produce rubber tubing with near-perfect inside diameters
  • Vulcanized spliced and rubber extrusions
  • Mil-Spec and custom markings

Common Extrusion Profiles


3D Shape of Rectangular Rubber Dock Bumper Profile


3D Shape of Cylindrical Rubber Dock Bumper Profile


3D Shape of Trapezoidal Rubber Dock Bumper Profile


3D Shape of A-Shaped Rubber Dock Bumper Profile

Hollow Rectangular:

3D Shape of Hollow Rectangular Rubber Dock Bumper Profile

Winged Cylindrical:

3D Shape of Winged Cylindrical Rubber Dock Bumper Profile

Winged Trapezoidal:

3D Shape of Winged Trapezoidal Rubber Dock Bumper Profile


3D Shape of D-Shaped Rubber Dock Bumper Profile

Service Across Industries

Custom and standard profiles for aircraft door seals, cable jacketing, clamp cushions, tubing, hatch cover gaskets, silo hatch seals, and watertight seals are but a few examples of products WARCO extrudes for the military and for the aerospace industry.

Profile gasketing for sealing doors, window glazing channels, and shower openings in both residential and commercial building environments.

We extrude Windshield seals, camper shell boot seals, channels and fenders.

Diversity in Equipment

Pristine Material Handling. Profiles for conveyor systems and warehouse applications. Compounds can be formulated to meet industrial, as well as food grade applications -“From rocks to eggs!”

Our extrusion equipment is extremely versatile.

As the industry-leading specialists in rubber extrusions, we are capable of producing cable jacketing, O-ring cord stock, tubing, squares, rectangles, as well as irregular shapes in a wide variety of sizes. Rectangles can be up to 5 inches thick and 6 inches wide or 1 1/2 IN thick and 12 IN wide with cord diameters up to 7 IN.

Request a custom job

Blue Splicing Machines Combining White Rubber Extrusions Used in Coffee Machines

Splicing Specialists

Rubber extrusions can be spliced and vulcanized to form an endless variety of shapes. WARCO’s extensive splicing capabilities allow us to produce seals and gaskets for a broad array of aerospace, automotive, chemical processing, construction, food processing, industrial, oil and gas, wire and cable, as well as military applications.

Our Splicing Department personnel are experts in creating high-quality spliced products. Our spliced parts are hot vulcanized, creating a stronger bond than can be achieved with standard adhesives. WARCO formulates and mixes its own proprietary splice compounds for the specific rubber parts that we’re splicing. After the application of the splice compound, the parts are then placed in molds where heat and pressure are applied to hot vulcanize the material, ensuring a long-lasting, reliable product.

Advanced equipment and multiple cavity molds permit high-volume production of O-ring and various other shapes – including squares, rectangles, and irregular profiles – at a fraction of the cost of alternative production methods. Combinations of extruded and molded parts can be spliced as well, allowing limitless configurations; resulting in substantial savings in time and tooling costs of fully molded products.

Custom Extrusions & Splice Products

WARCO has been the source of a number of different custom formulations (over 4,000) and a variety of unique and diverse products. Our legacy of over 110 years in rubber manufacturing has allowed us to become true experts in extrusion & splice rubber manufacturing. Even if you do not know how our rubber can fulfill your application, our team has been trained to assist you and determine how our products can solve your problem. To get started, you can fill out the form below or contact a sales representative.


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