A UK wearables brand's overmoulded button assembly
Three separate parts, bonded together by hand, kept failing the drop test at the bond line. We moved the assembly to a single overmoulded part. The bond became structural, and the …
Read the recordAnonymised · what we've actually done
Project records.
Not case studies with named customers. Anonymised programmes we've genuinely delivered, described honestly — what the problem was, what we changed, and what the commercial shape looked like when it was working.
Why anonymised
Why anonymised, and why that's the honest choice.
Manufacturing customers don't like being named. For most of them, the part we make sits inside a product they market as their own, and drawing attention to us would blur the story they want to tell. That's their call, not ours.
So instead of pretending we have testimonials we don't, we describe the shape of each programme without naming the customer. The problem, the route chosen, the trade-offs, the commercial outcome. Enough for you to work out whether your project rhymes with one of ours.
If a specific record rhymes with your situation, contact us and we'll talk through where it fits and where it doesn't. We can usually connect you with a reference customer under NDA once a project is far enough along.
The records
12 programmes, anonymised, told honestly.
A medical device OEM's LSR gasket in volume
A sealing gasket for a housing on a device that gets held all day. Compression-moulded worked, but every part needed a hand-trim on the sealing face. At volume, that stopped scalin…
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A consumer audio brand's ear tip production
Small, soft, colour-critical parts that customers hold to their heads for hours. Hand-cast pilot samples proved the design; production tooling had to hold the feel and colour acros…
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A precision electronics maker's keypad batch
A silicone keypad mat for a hand-held industrial device. Buttons that had to feel decisive without being noisy, conductive contacts that had to make circuit closure reliably, batch…
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An automotive tier-2 supplier's moulded seal
A rubber sealing component supplied into a tier-1 that fits it into a vehicle. Not exotic; not complex; just needs to arrive when the build schedule needs it. That's harder than it…
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A haptics brand's silicone diaphragm
A precision-shaped silicone diaphragm that generates haptic feedback in a small consumer device. Prototype casting proved the design; production LSR held it stable across millions.
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A wellness product's silicone applicator tip
A soft silicone tip that fits on the end of a personal care device. Skin-contact, cleanable, colour-matched to the brand. Batch supply against a fluctuating retail programme.
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A UK sportswear brand's overmoulded whistle
A referee whistle with a soft silicone mouthpiece bonded to a rigid plastic body. Not glamorous; used in cold weather, wet weather, and everything else. It had to survive the seaso…
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An outdoor brand's rubber grip production
A textured rubber grip fitted to outdoor equipment. UV-stable, weather-resistant, comfortable in cold and wet conditions. Batch supply across a family of tools sharing a common gri…
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A domestic appliance OEM's silicone valve
A small silicone valve inside a domestic appliance. Not seen by the user, but does its job millions of times over the appliance's life. Long-run supply into a mature appliance prog…
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A marine equipment maker's sealed connector overmould
Salt water was finding its way along the cable jacket and into the connector. We replaced a potted joint and heat-shrink with a single silicone overmould designed to grip the jacke…
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An industrial pump maker's fabric-reinforced diaphragm
A long-standing diaphragm supplier had stopped supplying and the replacement parts from elsewhere were failing early. We re-tooled the diaphragm in compression with a properly posi…
Read the recordDesigned 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.
How overmoulding works
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