Bidford-on-Avon, Warwickshire. Mon to Fri.01789 224228

OEM route · discrete batches

Batch manufacturing.

For volumes measured in the hundreds or low thousands per batch, released on your schedule rather than ours. Bridge tooling, dedicated compression, or single-cavity LSR — whichever route gives you the right unit cost for the volume you actually need.

BatchesOn your schedule
Any routeRight-sized
Real quotesFor real volumes
UKMade

Why batch, not continuous

Because not every part needs a production line behind it.

Small batch silicone moulding setup with trays of limited-run parts
Small runs made without full production scale

Continuous production only makes sense when volume can justify the tooling investment. Below that threshold — for prototypes, bridge production, pilot runs, seasonal products, or long-tail spares — batch manufacturing gives you moulded parts at sensible unit cost without the tooling commitment.

The route depends on the batch size. A hundred parts a year is best served by compression moulding on a simple tool, or by casting for very small numbers. A few thousand a year justifies dedicated compression tooling with a modest cavity count. Ten thousand a year usually starts to make single-cavity LSR viable.

For customers scaling up from prototype to full production, batch is often the right first step. Prove the design at real volume without a continuous-production tool commitment; migrate to continuous once the volume forecast is confident.

For customers with a stable part they only need occasionally — a spare, a service part, a long-tail SKU — batch is often the right permanent answer. We hold the tool, run the batch when you order, and don't tie up your money in continuous scheduling.

Drill down

2 ways we run batch manufacturing.

Each variant has its own page with the specifics: where it fits, how we run it and what to send us.

Short-run batches

Not every part needs thousands. Some need a few hundred a year, made properly, with the same paperwork as a big programme.

Open this variant

Call-off scheduling

You know roughly how many parts you'll need over the year, but not exactly when. Call-off scheduling lets us plan production while you draw…

Open this variant

Three shapes of batch work

Where batch fits in your programme.

Bridge production

You've validated the design in prototype. You need real parts at real volume while the continuous-production tool is being cut. Batch bridges the gap without waste.

Pilot and market test

You want to test the market before committing to production tooling. Batch produces a real product to sell, on soft tooling that costs a fraction of continuous.

Spares and long-tail

You have a stable part with occasional demand. We hold the tool, run the batch when you order it, don't fill your warehouse with unused stock.

Open compression press with trays of separate silicone production batches
Detail: compression press open with the heated tool halves visible and an operator at the controls.

How a batch runs

From order to delivered parts.

The workflow is deliberately light. You order, we schedule, we mould, we ship. Paperwork is proportionate to the size and criticality of the batch.

  1. Order confirms the batch

    Volume, delivery date, material batch to use (or fresh if none specified). Priced against the tooling investment already made.

  2. Tool pulled from storage

    The tool is inspected, cleaned, and set on the press. Any wear that's crept in since the last batch is addressed before the run starts.

  3. Run scheduled and moulded

    The batch runs against your order. First-off inspected as usual; batch documentation matched to your existing programme paperwork.

  4. QC and pack to spec

    Parts inspected against the drawing and — if a golden sample exists — against the reference. Packed to your spec, ready for dispatch.

  5. Delivered to your date

    Batch delivered to the date agreed at order. Any changes flagged early rather than at delivery.

Steel tool, first-off parts and batch trays prepared for inspection
Tool, first-offs and batch parts ready

To quote it

What we need on batch enquiries.

01

The batch size

Not the annual volume — the batch you actually want to release. That drives route selection more than any other factor.

02

Frequency of batches

One-off, quarterly, whenever you need it. That determines whether we hold the tool, or whether it makes sense to run once and archive.

03

Tolerance for surprise

How much notice you can give for a repeat batch. That shapes how we schedule shared tooling and shared cell time.

04

Whether volume is stable

If volume is likely to grow, we'll flag the migration path from batch to continuous before you're forced into it.

Related routes

Where this connects.

Compression moulding

Solid silicone or rubber pre-formed, loaded into a heated steel tool, and pressed under cure. Sensible tooling cost, thousands of parts per tool, and…

Read more

Tooling and part continuity

For parts that will be in production for years — components inside a device family, sealing parts on long-lived equipment, consumer parts on a…

Read more

Post-processing and finishing

Deflash, trim, print, bond, assemble, inspect and pack. Everything that has to happen between the press opening and the part being ready for your…

Read more
Designed 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 ideas in pictures.

Which route suits your quantity

PrototypesHundredsThousandsTens of thousandsPrototype toolingCompression mouldingTransfer mouldingSolid silicone injectionLSR injection

Swipe to see the whole diagram

A general picture. Shape, material and detail also decide the route, and we talk it through with you.

From drawing to delivered parts

  1. 01Drawing or sampleYour part and where it is used
  2. 02Material and routeCompound and process agreed
  3. 03PrototypeReal parts to test
  4. 04Sign-offYou approve the samples
  5. 05Production toolBuilt for your volumes
  6. 06Batches and checksInspected and delivered

Swipe to see the whole diagram

Parts are signed off before production tooling is made, so there are no surprises later.

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.
The TCI design and project office.
The TCI design and project office.
The TCI workshop, with moulds on the bench mid-build.
The TCI workshop, with moulds on the bench mid-build.
A stack of TCI silicone moulds.
A stack of TCI silicone moulds.
  • Thomas LaneManaging Director
  • George PrestonDesign & Project Manager
  • Kelly BallingerHead of Partnerships
  • Jim AndertonProduction Manager
  • TheodoreEmployee Welfare
Meet the team