Windsor Moulding and Tooling Co


We are a long established Injection Moulding company providing customisedsolutions to your small batch moulding requirements. We have qualified, expert toolmakers to manufacture an individual tool, designed to suite your own specific needs. Our company can offer a package to include design and manufacture of mould tools and the production of mouldings. Whether your requirements are for small batch mouldings or for larger volumes we can deliver. This can include insert and encapsulation moulding utilizing our numerous and versatile manumouldmachines for small batch quantities or our automatic machines for the larger volume orders.

Prototype Moulding

We can also produce single mouldings for prototypes, R&D (research and development) and pre-production services.

We are a registered member of the ISO 9001 quality assurance scheme.

Insert Moulding

All our mouldings and inserts are always designed and constructed of the most suitable material to deliver the highest quality of product; whilst ensuring you still receive the most cost effective service. Our insert mouldings vary from large to miniature no matter what your needs we are able to assist you.

Bespoke Plastic Mouldings

Each project is scrutinised on its own merits, from product and tool design through to assembly. We work to provide the finest quality of finished components.

Existing Mould Tool

If you already have an existing tool we may be able to use it exactly as is; OR modify it to enable the continued use of your existing tool.

Moulding Assembly

If your project entails the use of multiple pieces we are able to assemble them into a complete finished unit on your behalf.

The supply of metal inserts can be supplied when required or your free issue inserts can be incorporated.


Manumoulds are an extremely versatile molding machine ideal for the use of low volume moulding. This is due to the economical type tooling where cores can be removed/unwound by hand, thus eliminating complicated and expensive hydraulics. These machines are manually operated. Inserts or loose cores do not create a problem; in fact, we specialisein this type of work (inset moulding). Mould sizes range from the 125mm vice size down to 65mm (2.5 inch) and smaller with adapters. Our screw manumoulds allow us to offer coloured components by master batching.


We are able to produce nearly any shape & design of plastic mouldings, including insert & encapsulation moulding. We also undertake post moulding operations e.g. machining in undercuts, both internal and external. Further machining operations are also available to maximise the longevity & productivity of your small batch mouldings.

Threaded Inserts

It is possible for us to produce both male and female threads (in plastic or metal).

Personalised Embossing

We are able to emboss each moulding with your OWN company logo OR part numbers:this allows for easy identification of your parts if required.


With our in house design, manufacturing and full toolmaking facilities which include Electrical discharge machines (E.D.M); we are able to offer competitively priced packages of mouldmaking and production of mouldings.

Due to our self-sufficiency we’re able to control the entire project from commencement to completion and therefore able to give reliable delivery dates of the finished product.

F.E.A (Finite Element Analysis)

Our F.E.A department offers a technical, mechanical engineering consultancy service headed by Mr. M Windsor BSc., MSc., C.ENG, IMECHE. Using finite element methods we perform design and failure analyses of mechanical components and can therefore isolate any potential problems. The experimental validations are performed on material properties defined within the code and the experimental validation of the final product or component, and it is these findings that confirm validity of the results.

  • Linear
  • Non-linear
  • Contact
  • Buckling
  • Transient or steady state heat transfer analysis

Fire Escape Ladders

One of our customers was so pleased with our support and high standard of service, we have now been asked to take joint ownership of the company. Banksies(Down and Out) fire escape ladders endeavor to protect both residential and commercial premises to save personnel from the risk of fire as well having been used in the aerospace industry including M.O.D (ministry of defense) flight simulators.

Technical Mouldings

Throughout our many years of experience we have served numerous industries ranging from the medical sector, electronic companies, fire safety, aerospace, motorsport and many more. We have delivered components to such companies as the BBC, Remington Razors and Schumacher remote control race cars. A large portion of our customers we have served for over 20 years and work hand in hand to improve and increase the efficiency of our clients products.


We manufacture from a wide range of predominantly engineering type materials both unfilled and reinforced; including carbon fibre. Nylon is a very widely used by our customers along with A.B.S, polycarbonate, P.P.S (polyphenylene sulphide) down to the commodity plastics such as polyethylene and polypropylene.


An extremely versatile material used for a wide range of products and can also be reinforced with glass fibre or carbon fibre for improved strength and rigidity.

A.B.S- Acrylonitril Butadiene Sytrene

An engineering plastic commonly used for electronic products, pipe work and is readily bonded to itself using ultra sonic wielding.


Clear tough and mostly scratch resistant, generally used for medical use, plastic bottles, it is also a good electrical insulator and has heat resistant properties.

Thermoplastic Elastomers

Thermoplastic Elastomer Mouldings offer a softer, more flexible; rubber type mouldings. This material is suitable for cable strainers, gromits and non-slip pads.

P.P.S-Polyphenylene Sulphide

Is a crystalline engineering thermoplastic with attributes such as heat resistance and rigidity as well as resistance to acids and alkalies. It is used readily in automotive applications, cooking appliances and sterile laboratory equipment.

Coloured Plastics

We are able to supply a wide range of vivid coloured polymers using a technique known as master batching. Master batching is where a colourant is added to the natural polymer and can be added to nearly all plastic materials

Roller Rockers

We have designed and manufactured the high tech Windsor 1.5 Roller Rockers for the B.L (British Leyland) A-series engines along with carbon fibre push rods for the same engine. These have been approved and recommended by none other than David Vizard the renowned motorsport engine builder. The Windsor Roller Rocker has been featured in numerous publications including “Tuning B.L-A-series engines” by David Vizard, “Auto performance”, March, 1984 (page 5) & Aug, 1984 (page 50-51), “Cars and Car Conversions”, Aug, 1984 (page 88-90), which all certify the high ratio rocker increase the performance of race performance engines. Typical values of BHP (brake horse power) race tuned engines are:

  • 850 cc   =       5-8 BHP
  • 1000cc  =       7-10 BHP
  • 1100cc  =       8-11 BHP
  • 1300cc  =       10-13 BHP
  • 1400cc  =       11-14 BH

**Plant list

Toolmaking Facilities - Spark & Wire Erosion, Surface Grinders, Turret Mills & Turret Mills with D.R.O, Horizontal Mills, Toolmakers, Universal Mill, Lathes, Equipment to compliment the above, Gas & Arc Wielding, Precision inspection equipment

Injection Moulding Equipment - 6 Manumolds including 2 Screw machines, Automatics: 50-100 Ton locking pressure, Shot Weights- 1 Gramme to 150 Grammes, Insert & Encapsulation moulding, Hot air re-circulatory dryers

**Polymer List

Material Name Abbreviation Trade Name Description Applications
Acrylic PMMA Diakon, Oroglas, Lucite, Plexiglas  Rigid, brittle, scratch resistant, usually clear but can be coloured, optical clarity, low/medium cost  Display stands, knobs, lenses, light housings, panels, reflectors, signs, shelves, trays
Acrylonitril Butadiene Sytrene ABS Cycolac, Magnum, Novodur, Terluran  Strong, flexible, low mould shrinkage (tight tolerances), chemical resistance, electroplating capability, naturally opaque, low/medium cost  Automotive (consoles, panels, trim, vents), boxes, gauges, housings, inhalers, toys
Polyamide 6 (Nylon) PA6 Akulon, Ultramid, Grilon  High strength, fatigue resistance, chemical resistance, low creep, low friction, almost opaque/white, medium/high cost  Bearings, bushings, gears, rollers, wheels
Polyamide 6/6 (Nylon) PA6/6 Kopa, Zytel, Radilon  High strength, fatigue resistance, chemical resistance, low creep, low friction, almost opaque/white, medium/high cost  Handles, levers, small housings, zip ties
Polyamide 11/12 (Nylon) PA 11/12 Rilsan, Grilamid  High strength, fatigue resistance, chemical resistance, low creep, low friction, almost opaque to clear, very high cost  Air filters, spectacle frames, safety masks
Polycarbonate PC Calibre, Lexan, Makrolon  Very tough, temperature resistance, dimensional stability, transparent, high cost  Automotive (panels, lenses, consoles), bottles, containers, housings, light covers, reflectors, safety helmets and shields
Polyester - Thermoplastic PBT, PET Celanex, Crastin, Lupox, Rynite, Valox  Rigid, heat resistance, chemical resistance, medium/high cost  Automotive (filters, handles, pumps), bearings, cams, electrical components (connectors, sensors), gears, housings, rollers, switches, valves
Polyether Sulphone PES Victrex, Udel  Tough, very high chemical resistance, clear, very high cost  Valves
Polyetherimide PEI Ultem  Heat resistance, flame resistance, transparent (amber colour) Electrical components (connectors, boards, switches), covers, shields, surgical tools
Polyethylene - Low Density LDPE Alkathene, Escorene, Novex  Lightweight, tough and flexible, excellent chemical resistance, natural waxy appearance, low cost Kitchenware, housings, covers, and containers
Polyphenylene Oxide PPO Noryl, Thermocomp, Vamporan  Tough, heat resistance, flame resistance, dimensional stability, low water absorption, electroplating capability, high cost  Automotive (housings, panels), electrical components, housings, plumbing components
Polyphenylene Sulphide PPS Ryton, Fortron  Very high strength, heat resistance, brown, very high cost  Bearings, covers, fuel system components, guides, switches, and shields 
Polypropylene PP Novolen, Appryl, Escorene  Lightweight, heat resistance, high chemical resistance, scratch resistance, natural waxy appearance, tough and stiff, low cost  Automotive (bumpers, covers, trim), bottles, caps, crates, handles, housings
Polystyrene –General Purpose GPPS  Lacqrene, Styron, Solarene  Brittle, transparent, low cost  Cosmetics, packaging, pens
Polystyrene - High impact HIPS Polystyrol, Kostil, Polystar  Impact strength, rigidity, toughness, dimensional stability, naturally translucent, low cost  Electronic housings, food containers, toys
Styrene Acrylonitrile SAN Luran, Arpylene, Starex  Stiff, brittle, chemical resistance, heat resistance, hydrolytically stable, transparent, low cost Housewares, knobs, syringes
Thermoplastic Elastomer/Rubber TPR Hytrel, Santoprene, Sarlink  Tough, flexible, high cost  Bushings, electrical components, seals, washers
Can we help?