Plastic Extrusion: The Smarter Way to Create Custom Plastic Profiles

Plastic Extrusion Explained

Let's go back to basics for a moment... What is Plastic extrusion is a continuous manufacturing process where melted plastic is pushed through a custom die to create a consistent profile shape. Once cooled and cut, these profiles can be used in countless ways — from construction trims and furniture edging to lighting components, seals and tubing.

It’s an incredibly efficient method, ideal for high-volume or repeatable parts. But the true value of plastic extrusion comes from the way it’s managed — and that’s where BWC brings clarity, flexibility, and control.

End-to-End Plastic Extrusion Service

At BWC Profiles, we don’t just extrude plastic — we manage the whole process under one roof. That means fewer suppliers, fewer headaches, and better outcomes for your business.

Design and Development

Every great profile starts with a great idea.

Our design support team offers assistance to help you refine your concept for manufacturability, strength, and cost-efficiency. We’ll look at factors such as wall thickness, material selection, and functional requirements to ensure your profile performs exactly as it should.

Prototyping and Sampling

Before committing to full production, we can produce rapid 3D-printed prototypes or short extrusion runs. This lets you test fit, function, and appearance before investing in tooling or large-scale manufacture — saving both time and money.

Precision Extrusion and Co-Extrusion

Our extrusion facility in the UK houses multiple lines capable of producing both rigid and flexible profiles, as well as co-extruded parts combining different materials or colours. Whether your design needs strength, flexibility, or aesthetic appeal, we can tailor the process to your exact needs.

Finishing and Fabrication

Once extruded, we can cut, drill, notch, mitre, tap, or machine your profiles in-house. We also offer custom packaging and finishing, meaning you receive parts that are installation-ready the moment they arrive.

Stockholding and Distribution

We know many customers don’t have the space — or the desire — to hold large quantities of stock. That’s why we provide secure warehousing, just-in-time call-off, and nationwide delivery from our 65,000 sq ft facility. You’ll get consistent supply, reduced lead times, and simplified logistics.

Why Choose BWC Profiles for Plastic Extrusion?

With many extrusion companies to choose from, here’s why more businesses are partnering with BWC Profiles:

• Experience and Expertise: Our team brings decades of know-how in plastic extrusion, tooling design, and precision manufacturing.

• Flexible Approach: From short runs to long production volumes, we tailor our service to your needs.

• Complete Control: Design, extrusion, finishing, and logistics all happen in one place — giving you one reliable partner instead of several subcontractors.

• Cost Efficiency: By streamlining the process, we eliminate unnecessary transport, handling, and waste, saving you time and budget.

• UK-Based Manufacturing: Proudly operating from our modern facility in the UK, we combine global capability with local support and shorter supply chains.

Applications for Plastic Extrusion

Our plastic extrusion services support an incredibly diverse range of industries and applications, including:

• Construction and Building Products – window trims, corner protectors, channels, and weather seals

• Furniture and Interiors – desk edging, cable management, and decorative profiles

• Horticulture and Agriculture – tubing, connectors, and irrigation systems

• Automotive and Transport – protective trims, seals, and interior mouldings

• Retail and Display – signage holders, lighting diffusers, and POS profiles

Whatever your sector, if you need reliable, consistent plastic profiles — we can deliver.

From Concept to Continuous Production

At BWC, our goal is to make plastic extrusion simple, reliable, and value-driven. Here’s how we guide you through the process:

1. Discuss your concept – share drawings or sketches (CAD preferred).

2. We review and advise – material choice, design feasibility, and tooling recommendations.

3. Prototype and refine – physical samples ensure the design works before full production.

4. Extrude and finish – using state-of-the-art equipment and quality control.

5. Store and deliver – with flexible stockholding and logistics support.

It’s all about taking your project from an idea on paper to a consistent, production-ready profile — without the complexity.

Let's Make it Happen!

Plastic extrusion isn’t just a manufacturing process; it’s an opportunity to innovate. With the right partner, you can improve performance, streamline supply chains, and bring better products to market faster.

At BWC Profiles, we’ve built our service around clarity, capability, and trust.
So whether you’re developing a new product or improving an existing design, our team is ready to help.

Talk to us today to discuss your next plastic extrusion project — and discover how BWC can make it simpler, smarter, and stronger from start to finish.