More cavities
A new tool, or added cavities to an existing base. See multi-cavity injection.
Silicone manufacturing guide
Scaling a silicone part to volume.
Your part is selling. Demand is climbing. The tool and process that worked for early batches start to strain. Here's how to scale without disrupting supply.
When to act
Three signals that volume has outgrown the setup.
Batches back to back
The tool is running continuously just to keep up.
Unit cost matters more
Your margins now depend on part cost, not just getting parts.
Single-tool risk
One damaged tool would stop your product shipping.
The options
Four ways to add capacity.
A second tool
Duplicate tooling for capacity and resilience.
Change process
Moving from compression to injection or LSR.
Automation
Automated demould and handling at high volumes.
The approach
How we manage a scale-up.
The rule is simple: the old supply keeps running until the new one has proved itself.
Model the options
Cost and capacity of each option set out plainly.
Build new tooling
While the existing tool keeps supplying.
Qualify
First articles and trial batches approved.
Transition
Volume moved across gradually.
The numbers
Scaling usually costs up front and saves over time.
New tooling is an investment that pays back through lower unit cost and reduced supply risk. We'll show you the payback against your forecast, not ours.
If your forecast is uncertain, a staged approach — adding a second tool now and more cavities later — often reduces the risk. See call-off scheduling for managing demand in between.
Keep reading
More guides from the workshop.
When to switch from HCR to LSR
Many silicone parts start life in HCR, compression or injection moulded. As volumes grow, LSR starts to look attractive. Here's…
Read the guideCompression, injection or LSR — which route fits your part?
Three routes, one part, one honest answer. This is the conversation we have with almost every OEM customer on the first call.…
Read the guideOvermoulding: when it saves you a step, and when it doesn't
Overmoulding, two-shot, and bonded assembly are all ways to end up with a silicone part attached to a rigid substrate. Each has a…
Read the guideDesigned and developed in the UK. UK moulding capability, with some higher-volume production placed with trusted partners where that's the right commercial answer.
At a glance
The idea in a picture.
Which route suits your quantity
Swipe to see the whole diagram
Get in touch
Tell us the part, the volume, and the timeline.
Rough annual volume, target unit price, and any deadlines. That's enough to work out whether compression, LSR injection or something else is the right tool.
Real people, a real workshop
You deal with the people who make it.
No call centre and no middlemen. When you contact TCI Products, you speak to the team who design, build and check your mould.
- A real Warwickshire workshopUnit 15, Waterloo Park, Bidford-on-Avon, Alcester B50 4JG.
- Real people on the phoneCall the team on 01789 224228, Monday to Friday.
- The same team on every jobDesign, production and aftercare come from the people you see here.
- Part of TCI GroupFive specialist brands, one engineering team. Visit TCI Group.
Thomas LaneManaging Director
George PrestonDesign & Project Manager
Kelly BallingerHead of Partnerships
Jim AndertonProduction Manager
TheodoreEmployee Welfare