Whether you’re looking to manufacture an existing profile, modify one of our extensive tooling options or develop a completely new design, Tubeway Extrusions has the experience and capability to support your project.
Manufacturing plastic extrusions from our Ipswich facility since 1957, we’ve developed one of the industry’s most comprehensive tooling catalogues alongside the technical expertise needed to deliver high-quality production runs efficiently and cost-effectively.
Made-to-Order Plastic Extrusions
Our custom production service is designed for customers requiring larger manufacturing runs, typically from around 500 metres upwards depending on the profile. By manufacturing directly to order, we’re able to offer greater flexibility, competitive pricing and a range of options not always available from stocked products.
Custom production can offer a number of advantages, including:
- Bespoke plastic extrusion profiles.
- Access to hundreds of existing tooling options.
- Custom cut lengths.
- Standard and colour-matched compounds.
- Tool modifications where appropriate.
- New tooling design and manufacture.
- Secondary operations such as adhesive tape application.
- Expert technical guidance throughout the project.
From Design to Production
If you’re developing a new product, our team can advise on profile design, material selection, tooling requirements and production considerations from the earliest stages of the project.
With decades of extrusion manufacturing experience, we can often identify ways to improve manufacturability, reduce tooling costs or utilise existing tooling where suitable. For completely new profiles, we also offer a dedicated tooling design and manufacture service, helping turn concepts into production-ready products.
How Plastic Extrusion Works
At its simplest, the extrusion process consists of four key stages:
- Extrusion – Plastic compound is heated and forced through a precision die, creating the required profile shape.
- Cooling – The profile passes through a water bath and forming system to cool and maintain its dimensions.
- Haul-Off – The profile is pulled through the production line at a controlled speed to ensure consistency.
- Cutting & Finishing – Profiles are cut, coiled or subjected to any required secondary operations before packing.
While the process itself is highly technical, our role is to make it straightforward for customers, providing practical advice and support at every stage. For further detail on the production process, take a look at our extrusion line process explainer document.
Production Runs vs Stock Products
Custom production is often the best choice when you require:
- Larger quantities.
- Specific cut lengths.
- Non-standard colours.
- Bespoke profiles.
- Profile modifications.
- The lowest cost per metre on volume runs.
Stocked products may be more suitable when:
- You need rapid delivery.
- You only require small quantities.
- You’re prototyping or testing a concept.
- A suitable profile already exists within our range.
Our team will always advise on the most practical and cost-effective route based on your requirements.
Start Your Project
Whether you’re looking for a production run of an existing profile or need support developing a completely bespoke extrusion, we’re here to help.
Contact our team today to discuss your requirements, request a quotation or explore the most suitable manufacturing option for your project.