Product Design Services


Product Design

We are product design engineers specialising in plastics product design. From product concept and plastic product design to prototype, Ledwell offers a complete solution to manufacturing whatever you need. Our design team uses cutting-edge CAD systems and Solidworks. These combined with decades of real world experience creating new designs or reverse engineering designs, ensure the best solution possible. We use Solidworks plastics software to analyse your design and plastic flow to make sure it moulds correctly. Even before its been manufactured you will have peace of mind that your designs are refined, reliable and ready to be produced.

Plastic Design Services Worldwide

Our bespoke plastic mould tooling and manufacturing has been used by clients far and wide. From local businesses to national and international clients, we’ve worked with well-known names including Tropicana, Nescafe & Smirnoff.

Process & Project Management

Our team will work with you through the following stages of our process to ensure we deliver top-quality service and top-quality products.

Plastic Pellets
The process begins with feeding plastic pellets into the hopper. These pellets are then transported forward by a screw inside the barrel over a one-way valve called the screw tip assembly.
Heater bands surrounding the barrel warm the plastic pellets. As they move forward, they melt, forming a molten plastic mass at the end of the screw in front f the one-way valve screw tip assembly.
Once molten, the plastic is injected into the mould cavity by the screw acting as a plunger.
Within the mould, the plastic solidifies, usually within a minute. Ejection: The mould opens, and ejector pins push the cooled part out before the mould closes to repeat the cycle.

Product Design Services FAQs

Our process involves initial consultation to understand your requirements, followed by concept development, CAD modelling, and design refinement using Solidworks software. We conduct plastic flow analysis to ensure proper moulding and then create prototypes for testing before finalising the design.
We use advanced CAD systems and Solidworks plastics software to analyse and refine designs, ensuring they are reliable and ready for manufacturing. Our engineers also apply decades of real-world experience to optimise designs for manufacturability.
Our design team uses cutting-edge CAD systems and Solidworks software. We also utilise Solidworks plastics software for flow analysis to ensure the best possible design and manufacturability.
Yes, we specialise in creating new designs and reverse engineering existing ones. Our team can analyse and redesign your current product for improved performance and manufacturability.
We use Solidworks plastics software to simulate plastic flow within the mould. This helps us identify and address potential issues before manufacturing, ensuring the final product moulds correctly and efficiently.
We have designed products for various industries, including food and beverage, consumer goods, and industrial applications. Our notable clients include Tropicana, Nescafe, and Smirnoff.
The timeline varies depending on the project’s complexity, but typically, the process from initial concept to prototype can take anywhere from a few weeks to a few months. We strive to provide accurate timelines during the initial consultation.
Yes, our design team focuses on creating efficient, cost-effective designs. We optimise designs for manufacturability, reducing material waste and production costs while maintaining high-quality standards.
Solidworks plastics software allows us to conduct detailed flow analyses, ensuring that the plastic will fill the mould correctly. This helps prevent defects, reduces the need for costly rework, and ensures a higher-quality final product.
Yes, we cater to both low-volume and high-volume production needs. Our flexible bespoke tooling and manufacturing capabilities allow us to provide tailored solutions for projects of all sizes.

Whatever you need, we’re here to make it

Fill in the enquiry form and our friendly team will get back to you as soon as possible.

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