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Plastic & Aluminium Fabrication

Precision CNC machining, cutting and secondary ops, delivered fast, repeatable, and ready to assemble.

BWC Profiles CNC Punching Icon

4- & 5-axis CNC centres
for high-precision profile work

BWC Profiles Up To 8m Lengths

Up to 8m lengths
(large-format machining capability)

BWC Profiles Free-Issue Machining

Free-issue machining available
(we can machine your supplied profiles)

BWC Profiles Established UK partner since 1999

Established UK partner since 1999

Machined profiles that fit first time and stay consistent at volume

 When your extrusion arrives, the real performance is in the machining: hole positions, slots, end-prep, tapping, and repeatability. We machine aluminium and PVC profiles using CNC process control built for tight tolerances and consistent production

Typical reasons customers come to us

  • You need repeatable accuracy across batches (fewer rejects, less rework).
  • You’re scaling and need a partner who can hold tolerances and throughput.
  • You want one supplier for extrusion + machining + finishing + delivery (less chasing).
  • You’ve got a complex feature set and need jigs/tooling designed for it.

Profile machining capabilities

We can complete multiple operations in a single CNC cycle, improving accuracy and reducing handling time. 

 

CNC operations we can run

 Slots • drilling • tapping • milling • cutting •deburring • chamfering • countersink • counterbore (plus more, depending on your profile and setup). 

4-axis & 5-axis machining for complex features

 Our 4-axis and 5-axis centres are built for precise, high-speed machining—ideal when you need multiple faces worked accurately and consistently. 

 

Jigs, aggregates & custom tooling

If the job is tricky, we engineer the setup: custom jigs and tooling to tighten tolerances, speed production, and achieve difficult features.

BWC Profiles Machine Profile Fabricator

Already have your profiles? We’ll machine them

 If you already have aluminium or plastic profiles in hand but need additional fabrication capacity or capability, we can take on free-issue work and return parts ready for your next stage. 

What to send to quote free-issue machining

  • Profile material + spec (alloy/PVC grade if known)

  • Drawing (PDF/STEP), feature list, and critical dimensions
  • Quantity (prototype + annual volume if possible)
  • Target delivery date + delivery postcode

Get In Touch

Drilling & Milling

Turn extrusions into ready-to-assemble components with precise CNC drilling & milling, repeatable results, fast turnaround, with clean finishes.

BWC Profiles Drilling Profile Fabrication CNC Machining

Drilling

Fast, accurate hole-making in aluminium and plastic extrusions, set up for repeatability at volume.

Whether you need simple clearance holes, complex multi-hole patterns, or precision features that must align across faces, our CNC drilling processes are built to deliver consistent results batch after batch.

BWC Profiles Milling Profile Fabrication CNC Machining

Milling

CNC milling to create slots, pockets, rebates and complex profile features, clean, consistent, and assembly-ready.

Milling is where profiles become components. From a simple slot to a detailed pocket with tight positional requirements, we machine features accurately and efficiently using 4- and 5-axis CNC capability, reducing handling, improving repeatability, and keeping parts flowing through production.

Extrusion CUTTING SERVICE

Cost-effective cutting for long lengths, short parts, and mitres, quick turnaround, and consistent quality.

 

BWC Profiles Precision Aluminium Profile Cut To Length

Cut to Length

It is usually most economical to extrude aluminium or plastic in long lengths to a rough tolerance, then recut as required to a specific optimized cutting list. We cut aluminium and plastic components from 5mm – 8mm in length with incredible accuracy and quality using CNC cutting equipment.

BWC Profiles Mitre Cutting Machine

Mitre Cutting

Our fully automatic double mitre cutting (at lengths of up to 5m, from 22.5 to 90 degrees for profiles with a cross-section of 150 x 150mm, and with a level of precision +/-0.1 degrees) is the ideal solution for any application where a precise aluminium frame with mitred corners is required.

BWC Profiles Short Length Cutting Machine GAA-600

Short Length Cutting

We offer a variety of special bulk automatic recutting of short components such as aluminium brackets, cleats, couplers, sash adaptors and tubes. These are available in lengths from 5mm in length to 300mm in length and all the way up to a 600mm saw for our biggest profiles!

Complete Profile fabrication solutions (beyond machining)

If your project needs more than CNC and cutting, we can bundle additional operations so your parts arrive finished and ready.

BWC Profiles Plastic Profiles Punching Machine

Profile Punching

Punching is a cost-effective way to achieve high volume fabrication. This usually involves bespoke tooling, and we have both inline and secondary punching facilities in-house depending on the complexity of the feature.

BWC Profiles Aluminium profile thermal breaking

Thermal Breaking

Thermal breaking uses small plastic strips to link internally and externally facing aluminium profiles in glazing applications. The plastic strip prevents cold bridging, and it is usually inserted in a process called profile rolling.

BWC Profiles Deburring Service

Deburring

Deburring both aluminium and plastic profiles either by hand, using a belt, brush or vibration is a great way to give a clean look and a ‘safe to handle’ aluminium component. We can offer various types of deburring to suit the level of quality finish required.

BWC Profiles Aluminium Profile Bending

Profile Bending

Aluminium and plastic profiles can be manipulated to follow a tightly defined curved. This highly specialised process is often used in architectural applications to achieve an organic fluidic structure. 

Our machining equipment

Dedicated machines with complex features and tolerances you can trust.

BWC Profiles Aluminium profile 4-axis Profile Machine

Extra Large 4-Axis Profile Machine Centre 300x150x8m

Mecal Kosmos MC305+

Added to the shop in January 2021, our new upgraded Kosmos machine centre can handle large profiles up to 300w x 150h x 8000l. It boasts a rigid tapping capability and can machine on 6 faces of an aluminium or plastic profile in a single cycle. Applications include milling, drilling, tapping, countersinking, and much more with excellent levels of precision and repeatability.

BWC Profiles MECAL 5-Axis CNC Machine

ARIEL- 5 MDT - 5 axis (X, Y, Z, C, A) managed by CNC

MECAL MC 304

Our 5-axis CNC machining centre is a complete machining solution that is designed for high-speed machining of aluminium and PVC. The machine will cut pieces to length, using the MDT clamp system independently and move cut pieces to determined locations within the machine to allow end machining (as well as the normal face and side workings). With dual loading zones for seamless production and a saw blade with a maximum diameter of 450 mm (17.71″).

BWC Profiles 4-Axis Aluminium Profile Mecal Falcon

Extra Fast 4-Axis Profile Machine Centre 300x150x8m

Mecal Falcon MC307

Our largest investment in fabrication equipment, taking our capabilities to the next level. With a bed size matching the MC305+, as well as axis speeds of up to 150 m/min, the MC307 can complete complex routines at lightning speed. In addition to unparalleled precision and repeatability, the added speed makes the Falcon perfect of jobs with a high number of distinct features, requiring a large number of tool changes.

BW Profiles Aluminium extrusion mitre saw

CNC Controlled 5m Fully Automatic 450mm Mitre Saw

Mecal Argus SW453 Plug

Double mitre saw with NC positioned outward tilting heads with a range of 22,5°-90° using powerful DC servo motors and heavy-duty reduction gearboxes. Ideal for applications where many different cutting angles are required. Excellent levels of precision and superb cutting quality. The fully automatic function allows us to cut kits of varying length with ease and economy.

BWC Profiles Standard 4-axis profile machine centre 200x200x8m

Standard 4-Axis CNC Profile Machine Centre 200x200x8m

Mecal Kosmos MC305

Our standard Mecal MC305 can machine profiles of 200w x 200h x 8000mm long to levels of accuracy as tight as +/-0.2mm nominally. The Kosmos can drill, mill, saw, tap, countersink, counterbore, chamfer, deburr and engrave. It offers an accurate, economical and repeatable means to deliver consistent standards of quality in all aluminium extrusion and plastic extrusion fabrication projects.

BWC Profiles Kingsland Punch Machine

Versatile Hydraulically Operated Punch

Kingsland 50P

Developed for maximum production purposes and efficiency, this versatile, hydraulically operated punching machine can be used for large hole punching, crimping, tube notching, bar bending, sheet bending, punch press applications. Capacities based on material strength of 450N/mm2. Largest hole capacities: 38mm diameter (standard) and 110mm diameter (optional).