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What is custom moulding?

Custom moulding is a large part of our business here at BPF Online. In fact, it was, at one point,...
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What is custom moulding?

Custom moulding is a large part of our business here at BPF Online. In fact, it was, at one point, the core of our business. These days we’re known as BPF Online but back in March 2020, we established Banbury Plastic Fittings Ltd. Our goal was to use the latest injection moulds to create unique and innovative component solutions in plastic through custom moulding for our clients.

Over the years, we’ve acquired a sister company Tepco Engineering, enabling us to develop our product range into metal components and accessories too. Owning both the metal fabrication and plastic fabrication we have complete control over the quality of products that we offer our customers. Despite acquiring Tepco, we’ve remained loyal to our plastic fabrication stronghold.

Why choose custom moulded components?

While off-the-shelf components are convenient, fast, and often cost-effective, sometimes it’s just not possible to find what you’re looking for. Maybe it’s the wrong size, or perhaps you have an idea of how something could work better or want to capitalise on a branding opportunity. That’s why we offer our customers custom moulding.

What is custom moulding?

Custom moulding involves the design and creation of steel or aluminium moulds that can then be used to create plastic items to a specific design or size.

At BPF Online, we’ve been offering custom moulding for 23 years, so our teams are experienced in designing and creating injection moulds and identifying the best materials to use to create your designed components.

The custom moulding process involves 3 stages:


Tooling is where the mould tool is created by our technical team. They work closely with you to identify your needs for the component and will create a mould that will deliver. Once the designed component is created, the moulds are tested and sampled to check they live up to BPF’s high standards.

Injection Stage

At the injection stage, we inject the moulding solution into the moulds to create the component piece. We have extensive experience using most injection moulded polymers which can be combined with flame retardants, anti-microbials and blowing agents to meet your specific product requirements.


In most cases plastic injection mouldings, once created the components need to either be machined or assembled with other components. This could include sonic welding, glueing and even multi-component assembly.

Why use BPF Online for your plastic moulding?

  • All our tools are run on the latest automated injection moulding machines for greater precision and faster, more cost-effective product runs.
  • Our machines run 24 hours a day for faster turnaround times and more efficient product runs.
  • Our machines run in clean-room conditions so we can be confident that we deliver consistent repeatability in quality-controlled environments.
  • Our machine capacity ranges from 22 to 360 tonnes, so we have equipment for a vast range of quantities and sizes of products.
  • We specify all types of thermoplastics ranging from sophisticated engineering polymers to basic commodity polymers in a wide range of colours so we can deliver the right type of fittings to meet your needs so you can be confident in your products.
  • We have teams onsite who can conduct secondary operations and add finishes such as assembly, drilling, printing, plating and even sorting. This enables us to offer a wide range of finishes including high gloss finishes, sparked finishes and etched finishes such as woodgrain and brushed effects.

For more specific questions about any of our custom plastic mouldings, you can chat with our friendly and trained advisors online. They will advise you on the most cost-effective route to getting the components you need in the specification that you require.

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