Plastic Injection Moulding East Midlands

Derby's world-class automotive and aerospace manufacturers demand precision and reliability. We supply high-precision auto and aerospace parts - from under-the-hood engine components to interior fittings - that meet rigorous industry standards. Our engineering expertise and quality controls align with the exacting requirements of aviation and automotive production, ensuring components that are durable, lightweight, and safe. East Midlands companies involved in vehicle manufacturing or aerospace innovation can trust our parts to perform under pressure, contributing to the safety and performance of their final products.

Leicester and the surrounding area boast a strong food and beverage sector. We produce food-safe, robust plastic packaging and containers that help keep food fresh and secure. Whether it's injection-moulded caps and closures, beverage crates, or packaging inserts, our materials are FDA-approved and suitable for direct food contact. We understand the importance of hygiene and consistency in packaging – our products are made to protect your goods and your consumers, all while streamlining your packaging process. For breweries, snack manufacturers, and other food producers in the East Midlands, we deliver packaging solutions that combine functionality with eye-catching quality.

Nottingham’s growing medical technology and life sciences sector relies on precise, high-quality plastic components for devices and equipment. Stephens Plastic Mouldings can manufacture medical-grade parts - such as casings for medical devices, laboratory equipment components, or even parts for assistive devices - with meticulous attention to detail. We can work with medical-grade plastics that offer sterility, biocompatibility, and durability. Our ISO-certified processes and traceability protocols ensure that these critical components meet the strict standards required in healthcare. East Midlands medical and pharmaceutical companies can depend on us for components that help improve patient care and innovation, all produced in a controlled, quality-driven environment.

The logistics hubs of Kettering, Northampton and the greater East Midlands region keep Britain’s supply chains moving. We support this sector by providing tough, reliable plastic products for material handling and distribution. This includes items like durable shipping containers, pallets and pallet components, storage bins, tote boxes, conveyor system parts, and custom plastic fixtures used in warehouses. Our injection moulded solutions are built to withstand heavy use, protecting goods in transit and improving efficiency in warehouses. By equipping distribution centers with long-lasting, lightweight alternatives to traditional materials, we help reduce costs and improve handling speeds. Companies managing warehouses and transport in the East Midlands trust our mouldings to perform day in and day out, contributing to smooth logistics operations.

Getting a quote is easy. You can contact our team by phone or email (or via the contact form on our website) to discuss your project details. Let us know your requirements - for example, the part design or concept, estimated order volume, and any specific materials or certifications needed. We will then provide you with a free, no-obligation quote. Our quotes are transparent and detailed, outlining the tooling cost (if a new mould is needed) and the per-unit cost for production. We aim to respond quickly to all quote requests - typically, you can expect a response within one business day. Even if your project is at an early concept stage, we’re happy to discuss rough estimates and options to help you plan your budget.

Lead times can vary depending on the complexity of the project and our production schedule, but we strive to deliver as fast as possible without compromising quality. If you need a new mould to be manufactured, the tooling phase might take a few weeks (often 2-6 weeks, depending on complexity and whether it’s aluminum or steel tooling). Once the mould is ready, initial sample parts will be produced for your approval. After approval, production can ramp up quickly. For repeat orders using an existing mould, lead times are much shorter - often just a couple of weeks or even days for in-stock materials. We keep commonly used plastics on hand and operate efficient machinery to meet tight deadlines. If you have a specific timeframe or urgent project, let us know; we always do our best to accommodate and can prioritize jobs when necessary. Our central location in the Midlands also means shipping to East Midlands locations is very fast - often next-day delivery once parts are produced.

We offer complete flexibility in order size. There is no strict minimum order quantity - we can produce single prototype pieces or small batches just as readily as large production runs. For example, if you only need 10 test pieces for R&D, we can do that. We regularly work on projects that start with a pilot run or low-volume market test. Conversely, we are fully capable of scaling up to mass production, manufacturing tens of thousands of units when required. Our facility is equipped to handle high volumes efficiently. Do keep in mind that very small runs might incur a proportionally higher cost per unit due to the fixed setup and tooling costs, but we will advise you on the most cost-effective approach. Often, we can suggest options like soft tooling or 3D-printed prototype moulds to create samples before investing in full production tooling. Whatever your quantity, we treat every order with equal importance and ensure you get top-quality parts.

Yes, absolutely. We understand that not all clients come with a production-ready CAD model - sometimes you just have a concept or a problem that needs solving. Our team provides end-to-end support, including product design and prototyping. We can work with you from the earliest stages of development: our design engineers will discuss your idea and help create a 3D CAD design of the part, optimizing it for injection moulding (ensuring proper draft angles, wall thickness, etc. for manufacturability). We also offer rapid prototyping services such as 3D printing or CNC machined prototypes, which allow you to test form and fit before committing to a full production mould. If needed, we can produce sample parts using techniques like vacuum casting or low-volume injection trials to validate the design. This collaborative approach helps ensure that by the time we move to mass production, you are confident in the design and functionality of your product. In short, even if you’re starting from scratch with just an idea, we can guide you through design, prototyping, and into full injection moulding production.

We work with a wide range of thermoplastic materials, and we will recommend the best material based on your project’s requirements. Common materials we use include ABS (a tough, impact-resistant plastic great for enclosures and automotive parts), Polypropylene (a flexible, food-safe plastic often used in packaging and containers), Polyethylene (in various densities, for everything from bottles to rugged crates), Polycarbonate (a clear, extremely durable plastic ideal for lenses or transparent parts), Nylon/Polyamides (strong and heat-resistant, used in engineering components), PET (often for food and beverage containers), PVC, Acrylic, and many more. We can also mould engineering and high-performance plastics like PEEK or glass-filled nylon if your application demands higher temperature or strength properties. If you require materials with specific certifications - for example, food-grade, medical-grade, or flame-retardant plastics - we can source those as well.

Additionally, we handle various additives and composites:
Need parts with UV resistance, anti-static properties, or certain colors?
We can incorporate masterbatch additives or use pre-compounded specialty resins. Our team will work with you to choose a material that balances performance, cost, and any regulatory compliance. If you’re not sure which plastic is right for your product, we’re happy to advise based on our extensive materials experience.

Yes. We regularly produce components for the food & beverage and medical industries, so we are familiar with the standards and materials required to ensure safety and compliance. For food-safe parts, we use certified food-grade plastics (such as certain grades of polypropylene, polyethylene, etc.) and maintain a clean manufacturing process to avoid contamination. Our ISO 9001 quality management system helps ensure traceability and consistency, which is important for food packaging and utensils. For medical applications, we can use medical-grade resins that meet ISO 10993 or USP Class VI biocompatibility standards, and we can adhere to any specific cleanliness protocols you might need (for example, using an ISO Class 8 cleanroom for moulding if required, or packaging parts in a controlled environment). We understand the critical nature of medical parts - lives can depend on them - so we take extra care with quality control (including possible additional inspections, sterilization-ready packaging, etc.). If you have particular regulatory or compliance requirements, let us know, and we will incorporate those into our process. Our experience with these sectors means we know how to deliver safe, compliant products that you and your end-users can trust.

We serve the entire East Midlands region and beyond. This includes all counties and major towns/cities in the area. Whether your business is located in Derbyshire, Leicestershire, Nottinghamshire, Lincolnshire, Northamptonshire, or Rutland, we have you covered. We frequently deliver to cities such as Derby, Leicester, Nottingham, Northampton, Kettering, Lincoln, and the surrounding areas. In fact, we serve the West Midlands and the rest of the UK as well, so even if you have multiple facilities or move premises, we can continue to support you wherever you are. Our Midlands location allows us to reach most East Midlands clients with next-day delivery, and in many cases we can even arrange same-day courier dispatch for urgent needs. So, no matter if you are in a large industrial hub or a rural business park in the East Midlands, you can count on Stephens Plastic Mouldings for prompt service. (For international clients, we also offer shipping and have experience exporting our products, but our focus and strength is servicing UK-based companies that want the convenience of a local supplier.)

The cost of injection moulding depends on a few factors:
The complexity of the part, the type of material, the size of the order, and whether a new mould tool needs to be made.

There are typically two cost components:
The upfront cost for tooling (designing and manufacturing the mould) and the per-unit production cost. Tooling is a one-time investment - it can range from a couple thousand pounds for a simple aluminium mould to several tens of thousands for a large, multi-cavity steel mould with very precise features. The good news is that once the mould is made, the per-part cost is relatively low.
For example, if you’re producing large volumes, the cost per unit might be just pennies or a few pounds, depending on material and cycle time. If you only need a small quantity, the per-unit cost will be higher because it needs to absorb the tooling and setup costs. We always strive to offer competitive pricing and will work with you to maximize value. For instance, we might suggest design tweaks to simplify the mould (reducing tooling cost) or identify opportunities to use a more cost-effective material that still meets your requirements. We can also accommodate tooling payment plans or spread the tooling cost into the part price if that helps your cash flow.

Overall, injection moulding becomes very cost-effective for production runs once the tooling is in place - especially for quantities in the hundreds and above. The best way to get an accurate idea of cost is to contact us with your project details; we'll provide a detailed quote breaking down all costs, so you know exactly what to expect with no surprises. Remember, our quotes are free - so feel free to reach out even if you’re just budgeting or exploring the feasibility of a project.

Choosing a UK-based injection moulding company offers several advantages in terms of quality, reliability, and convenience. Firstly, communication is easier - you’re working with a team in your own country, speaking the same language, in your time zone, which means faster responses and no overnight lags. You can easily visit our facility or have face-to-face meetings, and we fully understand UK standards and regulations. Secondly, lead times and flexibility are significantly improved. Without the need for international shipping or customs delays, you can get your parts much faster and adjust orders more quickly. If you suddenly need an extra batch of components or a design change, we can respond in days rather than the weeks or months it might take with an overseas factory. This gives you greater certainty and control over your supply chain. Thirdly, quality assurance tends to be higher and more transparent - you can trust our ISO 9001 certified processes, and you have legal recourse under UK laws if any issues arise. We have a reputation to uphold in our local market, so we are highly motivated to maintain strict quality and trustworthiness. Additionally, there are no hidden costs such as import duties, international freight, or currency exchange fluctuations when you deal locally - the price we quote is what you pay. Finally, by working with a UK manufacturer, you’re supporting the local economy and manufacturing sector. Many of our clients find value in being able to say their products are "Made in Britain" with components from a British supplier, which can be a selling point for their own customers.