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Recent projects

Projects that show what’s possible.

Browse real moulding projects across aerospace, consumer products, food, wax, soap and concrete to see how different materials, shapes and tooling challenges were approached.

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Explore our project work

This section brings together case studies from across TCI Mouldings, from delicate detail work to tricky undercuts, flat castings and production tools with moulded features. It is here to help you see how similar problems have been solved in practice.

If you want the full picture, start with All projects. If you already have a similar part or process in mind, choose the page that matches your product, material or moulding challenge most closely.

Illustrative example:

All projects

Every case study in one place

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Illustrative example:

Aerospace 0.2 mm feature

Cast a feature finer than a paperclip

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Illustrative example:

Jewellery master, inhibited cure

Sulphur on the pattern, no cure

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Illustrative example:

Pine cone tooling

A mould that is all undercuts

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Illustrative example:

Silicone ear pads

Compression with a seal lip

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Illustrative example:

Watch strap logos

Injection tool with a moulded mark

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Illustrative example:

Electrical patch, flat

Casting it dead flat first time

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Illustrative example:

Chocolate bar logo mould

polycarbonate-alternative silicone chocolate bar mould with a moulded logo

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Illustrative example:

Two-part vessel candle mould

two-part cast silicone mould for a container candle vessel

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Illustrative example:

Large soap loaf mould

large-capacity cold-process soap loaf mould with a moulded relief base

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Illustrative example:

Tapered-wall pillar candle mould

reusable cast silicone mould for a tapered-wall pillar candle

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Illustrative example:

20-cavity tealight mould

20-cavity food-grade silicone tealight mould for wholesale wax pouring

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Illustrative example:

Concrete planter mould with drainage detail

cast silicone mould for a concrete planter with an integral drainage hole and…

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If you are not sure which project is closest to your brief, get in touch and we will point you in the right direction.

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Real people, a real workshop

You deal with the people who make it.

No call centre and no middlemen. When you contact TCI Mouldings, 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.
A stack of TCI silicone moulds.
A stack of TCI silicone moulds.
The TCI workshop, with moulds on the bench mid-build.
The TCI workshop, with moulds on the bench mid-build.
Silicone wax melt moulds made by TCI Mouldings.
Silicone wax melt moulds made by TCI Mouldings.
  • Thomas LaneManaging Director
  • George PrestonDesign & Project Manager
  • Kelly BallingerHead of Partnerships
  • Jim AndertonProduction Manager
  • TheodoreEmployee Welfare
Meet the team