Company details for:

Bray Plastics Ltd

Name: Bray Plastics Ltd
Address: Cherrycourt Way, Leighton Buzzard, Bedfordshire, LU7 4UH, United Kingdom
Telephone: 01525 219100
Rating: 5.00

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Cherrycourt Way,
Leighton Buzzard,
Bedfordshire,
LU7 4UH,
United Kingdom

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Products / Services

CNC Milling & Routing

Our precision CNC routing and milling services are used for a wide range of plastic and metal materials, with a fast turnaround. We can machine both simple 2D designs from flat sheet or more complex 3D, contoured shapes.

CNC milling and routing is perfect for producing high quality and extremely accurate parts for either prototypes or the complete production parts. It is also perfect for adding details such as holes, cutouts and recesses to vacuum formings and laser cut parts.

We have 3 CNC routers and have the ability to machine up to 3000x1500x100mm as well as being able to machine “off-bed”.

CNC Turning

Our precision CNC turning services are used for producing highly accurate cylindrical parts from metal and plastic bar and tube. Often this involves side holes and flats which can be achieved with live tooling attachments. We have the ability to turn up to 300mm diameter x 1.5m long.

Plastic Fabrication

Although fabrication can be used to cover all aspects of plastic processing (including machining, turning etc), in this section we will be focusing on the other fabrication services we offer.

Plastics can be formed, welded and bent in much the same way as steels. These fabricating techniques allow designers to take advantage of plastic’s properties of corrosive resistance, finish, weight, Wi-Fi compatibility strength and clarity. We can also flame polish or buff suitable materials to enhance surface finish.

When it comes to joining plastic parts together, we can either use:-

Chemical bond − This provides excellent mechanical strength by “melting” the surfaces being bonded to create one cohesive part. MEK or methylene chloride are some of the more common chemicals used for bonding in this process. Ideal for clear materials such as acrylic and polycarbonate as well as ABS and HIPS
Structural bond − This process is often undertaken using a 2 part adhesive. Structural adhesive come in many different types for specific uses, enabling the bonding of many different plastics.
Welding − Welding uses a filler rod, similar to metal welding. The heat then melts the filler rod into the 2 plastic surfaces to be joined. Ideal for PVC, polypropylene, and polyethylene.
Mechanical fixings − These can be metal or plastic off-the-shelf fastenings. These can be simple nuts and bolts or screws into metal inserts which provide greater thread strength

Our understanding of the vast array of qualities available in modern plastics and the different processing techniques allows us to provide invaluable advice and find the most suitable and cost effective technique for your project. We actively source suitable environmentally-friendly options using recycled and recyclable plastics where possible.

Vacuum Forming & Moulding

Vacuum forming (also known as thermoforming) is the process of heating a plastic sheet until soft then raising the mould into the softened plastic sheet while applying vacuum for pull the sheet tightly round the mould. Once cooled, the mould is then released from the forming which can then be cut out of the excess sheet and finished as required.

Vacuum forming of plastics can be an extremely cost effective way of overcoming a number of problems that face designers, with tooling for short runs easily justified. We produce our own tooling , which means our turnaround times are short, and we can supply prototypes to production runs in a variety of thermoplastic materials.

We can advise on materials and how this process may benefit your requirement from concept through to production.

We have the ability to form sizes from 100 x 100mm to 2m x 1.2m.

Laser Cutting

We operate 2 CO2 lasers. Both are 150 watts and enable us to cut and engrave fine detail into a wide range of materials including plastics and adhesive-backed foams. Particularly useful for cutting complex shapes into hard to cut materials (e.g. Velcro, and leather) we have found these lasers to be an extremely useful tool to offer our customers.

We have 2 150wattt CO2 lasers with the ability to cut up to 2500 x 1500mm sheets.

Prototyping & Tooling

Our range of production equipment allied to our skill set enables us to offer prototyping services from single components through to assemblies. We can machine tooling from drawings or CAD files. Bray Plastics have a highly-skilled and experienced team providing the very best tooling to meet the individual needs of our clients.

3D Printing

3D printing is an additive manufacturing process where plastic filament, resin or powder is layered up to create the final object. It can be an invaluable resource when it comes to prototyping and low volume runs of complicated parts that would otherwise require expective injection moulding tooling. We have 3 print options; SLA (resin), MJF (Multi-jet fusion) or SLS (powder)

Materials

There’s a huge range of plastics to choose from for your project. Here’s a quick reference guide to help you find the most suitable. We have specialist knowledge of the world of plastic and will be able to advise you on the best material for your use depending on the environment. Consider the industry your components will be used in, will you require an extreme working temperature, chemical resistance or electrical insulation? Do you need something that can withstand high impact or flexibility? Is there a requirement that you feel will be difficult to fulfill? Just give us a ring and we’ll definitely be able to help you with your query.

Enclosures Customisation

At Bray Plastics we provide high-quality enclosure solutions for electronics, instrumentation, communications, industrial controls, and specialist applications.

From modifying standard enclosures to designing and manufacturing fully bespoke housings, our complete in-house service covers design, CNC machining, fabrication, finishing, and assembly — delivering enclosures that are fit for purpose, great looking, and made in the UK.

Off-the-Shelf Enclosures

We collaborate with all the leading enclosure manufacturers to swiftly and competitively source the ideal product for your project.

Our comprehensive network enables us to provide high-quality enclosures from top brands, eliminating the need for you to reach out to multiple suppliers.

Enclosure Product Range

Enclosures are integral across a multitude of industries — including electronics, electrical, automotive, medical, rail, instrumentation, and beyond. We provide tailored solutions for almost any environment and application.

Our Extensive Range Includes:

Potting Boxes — compact protection for small electronic devices
Aluminium Extrusions — robust profiles that effectively dissipate heat and boast excellent machinability
Flanged Enclosures — simple wall or surface mounting options
Rectangular & Project Boxes — versatile housings for general use
Handheld Enclosures — ergonomic designs perfect for portable devices
Desk & Wall-Mounted Units — offering a professional appearance for control and display applications
IP-Rated Enclosures — providing effective dust and waterproof protection (IP65, IP67, IP68)
Metal Enclosures — crafted from steel, stainless steel, and die-cast aluminium
Specialist Ranges — featuring transparent lids, EMI shielding, high-impact, and flame-retardant options

Enclosure Materials

Different applications require specific material properties. We collaborate with a vast array of materials to recommend the optimal choice for strength, weight, cost, aesthetics, and environmental performance.

Materials We Use & Supply:

Aluminium — offers excellent thermal conductivity, is lightweight, corrosion-resistant, and easy to machine
ABS — robust, cost-effective, and provides good impact resistance
Polycarbonate (PC) — characterised by high impact strength, with transparent options available
Acrylic Capped ABS — provides a premium high-gloss finish
Polypropylene (PP) — known for its chemical resistance and lightweight properties
Polyester & GRP — designed for heavy-duty outdoor and industrial applications
Die-cast Aluminium & Zinc — utilised in high-pressure or EMI applications
Other Engineering Plastics — including flame-retardant grades

Material Selection Guidance

Indoor versus outdoor use
IP rating and sealing requirements
Heat dissipation needs
Chemical or UV exposure concerns
Aesthetic finish (matt, gloss, textured, painted)
Cost and volume considerations

Case Studies: ProEconomy

Project: Revamping and Re-engineering of Water Treatment Facility.

Case Studies: AES Cirrus

Project: Manufacture panels and components for the healthcare sector.

Case Studies: Mechline Developments

Project: Development and Production of a Commercial Kitchen Dispenser Housing.

Case Studies: EKA

Project: NATO Recovery Vehicle.

Case Studies: Inzpire Ltd

Project: Military Pilot Tablet Knee Mount.

Introducing our premium Military Pilot Tablet Knee Mount, specifically designed to enhance operational efficiency and provide unparalleled convenience for military pilots. This robust and durable accessory securely holds your tablet in a comfortable and accessible position, allowing for seamless interaction during flights. Crafted with top-quality materials, our knee mount ensures stability and reliability, even in the most demanding environments.

Optimised for easy installation and compatibility with various tablet models, our Military Pilot Tablet Knee Mount is an essential tool for enhancing situational awareness and improving productivity in the cockpit. Experience the difference today and elevate your mission performance with this indispensable piece of equipment.

Case Studies: Aston Martin

Project: Reverse Engineering Services for Enhanced Product Development.

Case Studies: World Leader in Polishing Optics

Project: Replacement of a stainless steel collection tray with a vacuum-formed slurry collection tray.

Case Studies: Metrology Equipment Manufacturer

Project: Microfocal X-ray Cabinet for Precision Imaging.

Case Studies: World Leaders in Refrigerated Packing

Project: To manufacture prototype components machined from styrene and created through vacuum forming techniques, delivered within tight timelines.

About us

Bray Plastics Ltd is a team of skilled engineers specialising in custom plastic fabrication.

With over 30 years of experience in developing and manufacturing products and custom parts for a diverse range of clients, we offer a comprehensive and expert "turnkey" service. From design and prototyping to low-medium volume production and final assembly, we are equipped to deliver the ideal solution for your needs.

Our Services Include:

CNC Turning

Precision is assured. Our expertise enables us to successfully execute custom, complex projects for demanding environments. We have the ability to turn up to 300mm diameter x 1.5m long.

CNC Milling & Routing

Expertly engineered components in a variety of plastics and metals with quick turnaround times. We have 3 CNC routers and have the ability to machine up to 3000x1500x100mm as well as being able to machine “off-bed”.

Fabrication

Specialists in diverse plastic fabrication methods, including machining, routing, welding, with extensive expertise in material specifications, solvent and structural adhesives, and mechanical joining techniques.

Vacuum Forming

This cost-effective forming technique is suitable for both small and large components and is widely used across various industries. We have the ability to form sizes from 100 x 100mm to 2m x 1.2m.

Prototyping & Tooling

Our production equipment and expertise allow us to provide prototyping services ranging from single components to complete assemblies.

3D Printing

We have 3 print options; SLA (resin), MJF (Multi-jet fusion) or SLS (powder).

Laser Cutting

We have 2 150wattt CO2 lasers with the ability to cut up to 2500 x 1500mm sheets.

Enclosures

We machine both injection-moulded and cast aluminium enclosures, and also design, manufacture, source, and modify custom enclosures.

We provide a wide range of services, covering every stage of the production process. We offer bespoke machining and specialist plastic fabrications. Using our knowledge and expertise, working with you every step of the way, to find the best solutions.

We consistently assess the environmental impact of our projects by actively sourcing recycled and recyclable materials and promoting the circular economy.

Reach out to us today at 01525 219100 to discuss your project and discover how we can help you find the ideal solution!