Custom Plastic Extrusion Manufacturer

Experts in custom plastic extrusions profiles

As well as standard profiles, we manufacture and supply custom plastic extrusions for many applications. Sometimes your project has an unusual profile or requires a unique shape. With a custom profile, you can achieve a smooth finish in any space or project.

With over 35 years of industry experience, we are noted for our ability to create bespoke plastic extrusions that are customised to your individual needs. Get your choice of material with custom profiles in PVC, PET, HDPE, EVA and Polycarbonate available on request.

We use high tech equipment and custom design tools made in-house to develop and manufacture custom extrusions to your precise requirements.

What do we need from you?

In order to help with your enquiry, we would need a dimensional drawing, preferably in PDF and DXF format if possible. Alternatively, if you do not have this information to hand, please send us a sample of your existing product so we can ensure we quote like-for-like.

Ideally, any indication of annual meterage would help us achieve the best possible pricing for your requirement and alongside this, we would need information such as material, colour, required length(s) and any packing specifications.

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Built for a Range of Industries in the UK & Overseas

We provide custom extrusions to a wide spectrum of industries. From our manufacturing centre in Derbyshire, we deliver across the UK and overseas to manufacturers, decorators, builders and more. Some of the industries we serve are covered below.

Retail / Shop-fitting

Covering hard edges, cables or shelving gaps with plastic trims and extrusions can give your shop floor a professional and clean finish, ensuring safety and ease of cleaning at all times. In bespoke shop fitting designs, plastic custom extrusions may be required to fit the needs of the design.

Building & Construction

Plastic extrusions or trims for conservatory, canopy or other modular buildings are a key material, providing secure fixings, sealing gaps and smoothing joins.

Electrical Manufacturing

In lighting or other electronics, plastic extrusions support a wide range of fixtures and fittings.

Sports and Leisure

Manufacturers of sport equipment such as treadmills or cycle machines use plastic extrusions and profile in all sorts of custom shapes to provide uniform edges and covers.

Explore our complete list of sectors we serve here.

Custom-Design Tools Made In-House To Fit All Requirements

We specialise in durable, cost-effective custom extrusions in different types of plastics. To do this, we invest in the latest technologies and equipment to develop our extrusion manufacturing processes and meet customer requirements to a tight tolerance.

We create our tooling and dies in-house to provide maximum efficiency when producing custom extrusions. This means we don’t need to wait for our dies or casts to be manufactured elsewhere to start creating custom plastic trims, angles or other extrusions. Thanks to our in-house tooling, we can offer our customers a fast turnaround and modify the designs as required.

Colour-Matching Services Available

Add the finishing touch to your project with perfect colour matching. Plastic extrusions are easily manufactured in white, black, yellow or clear plastic, but for more unusual colours, they can be hard to come by.

At Windmill Extrusions, we have an extensive range of standard colours readily available and are also able to support our customers’ vision by providing colour-matching services, so the extrusions we create match exactly for a great visual impact.

Our Custom Plastic Extrusion Process

Quote: You provide us your requirements, and we can assist you with putting together a quotation that you’re happy with.

Design: Your concept is drawn up using Computer-Aided Design technology, enabling us to tweak the final design to your exact specifications.

Tooling: Our state-of-the-art wire erosion machine allows us to complete tooling projects quickly whilst maintaining the high level of accuracy expected.

Machining: One of our Toolroom Machinists applies minor adjustments to part of the die, ensuring the material forms the correct shape.

Extrusion: The profile is extruded by our Development Engineer to ensure no further amendments need to be made.

Completion: From concept to completion: The initial design with the completed die plates and the profile sample submitted for review.

Can Any Plastic Material Be Extruded?

Many different materials can be used for custom extrusions, in order to fulfil your needs precisely. A wide range of products can be created using our expert plastic extrusion services.

These include:

Conventional PVC – Polyvinyl Chloride is a common material for profiles extrusions, being a high-strength thermoplastic material.
Polycarbonate (PC) – A strong, resilient plastic which can withstand extreme temperatures: perfect for partitions, faceshields, retail and display shelving, tubing, lighting and more.
uPVC – This is the same as PVC but it is ‘unplasticised’. It is strong but lightweight and requires very little maintenance.
Polypropylene (PP) – A tough, rigid and crystalline thermoplastic with high durability and impact strength, used for window components, cutting boards, microwavable containers and medical applications.
Low-density polyethylene (LDPE) – A thermoplastic that is robust yet flexible. LDPE can create plastic extrusions with high flexibility, perfect for piping in drinking water systems as it does not impart odour to liquids.
Polyethylene terephthalate (PET) – A clear, strong, lightweight and 100% recyclable plastic
Specialised thermoplastic elastomers – Materials which combine ease of processing with flexibility of elastomers.
Ethylene vinyl acetate (EVA) – A flexible rubbery plastic with good chemical resistance and a high friction coefficient, used for medical tubing, gaskets, hoses and anti-vibration padding.
High-density polyethylene (HDPE) – A low friction, waterproof and chemically resistant plastic used for tubing, crates and wire jacketing.

If you’re not sure which plastic is best suited for your project, feel free to contact us to discuss it with our team. We’re here to help.

Find our page of materials we utilise here.

Committed to sustainability

As the world of plastic changes, we are keen to move towards more sustainable practices and materials. We currently recycle all of our scrap materials in-house where possible and are also working with industry leads to move towards more sustainable practices and green solutions. We also currently offer alternative recyclable materials for some items upon request and can offer advice on where to recycle PVC if required.

Why Choose Windmill Extrusions?

35 years of industry experience
Based in Derbyshire in the heart of England, delivering across the whole of the UK and overseas
Creating custom plastic extrusions in any colour, customised to your individual needs
Wide range of extrusion materials
Durable, cost-effective bespoke extrusions from concept to completion

Unsure? Ask Our Expert Team!

Our friendly team are highly knowledgeable and experienced. We’ve built a reputation for delivering excellent customer service and making the highest quality custom plastic extrusions with our own purpose-built tooling. Contact us today with any enquiries you might have.