Custom Plastic Extrusion

Some plastic extrusions are new designs to meet a particular purpose (known as custom plastic extrusions), which cannot be met by standard or stock designs. This section is Your Guide to our process – “From the idea to the extrusion”.

TP Extrusions have gained a reputation for being able to help with custom plastic extrusion design, including large and complex profiles in a variety of materials, including co-extrusions.

The following outlines how the custom plastic extrusion process works ;-


TP Extrusions may be able to assist you at this stage, as we have many years of experience of custom plastic extrusion design and material properties. Please click for an introduction to custom plastic extrusion design and for details of thermoplastic materials.


From fully dimensioned drawings, the dies and tools required for your custom plastic extrusion can be made. The lead time necessary will vary according to complexity, but will be discussed and agreed.


The plastic extrusion tooling undergoes trials, producing samples for submission to you.


Following any necessary modifications to the plastic extrusion, you approve the samples and bulk production can be scheduled.

Production of your custom plastic extrusion

This will generally be within 2 weeks of sample approval.

Recent applications for custom plastic extrusions

Some recent applications that TP Extrusions have helped with custom plastic extrusions include ;-

1] Strengthening bars for injection moulded crates
2] Co-extruded hinged LED light strip carriers
3] Large panel connecting profiles for a world famous London store
4] Complex hollow profile for use on doorways at Arsenal’s stadium
5] Double ticket profile with co-extruded hinge
6] Lighting trims for a British sports car manufacturer
7] Custom profiles for TV shows including Big Brother and Eastenders
8] Profiles with chrome foils for use on vintage cars.

Hopefully this list illustrates the diversity of industries in which we can work. Our customers range from blue chip household names to the smallest start up business.

We very much welcome any enquiries that you may have for custom plastic extrusions.

To enable us to quote accurately, please can you provide the following information wherever possible :-

1. Sketch / Drawing or sample
2. Colour required – sample, RAL, Pantone or BS
3. Material required
4. Quantity required – both for samples and bulk order
5. Length(s) required”

Gallery of Custom Plastic Extrusions

below are some examples of custom plastic extrusions. Please click on an image to see large view – move your mouse over the image towards the top (right) to select ‘next’ or top (left) ‘previous’: