The Solution is multiple processes...

Clear, flexible, metal AND Plastic all required for production part!

From design to production, Plunkett's manage multiple manufacturing processes.


Having been involved in a cold store lighting project for a client, Olivewood recognised an opportunity to take a completely fresh look at how cold store lighting works in order to increase performance, reduce costs, refine assembly processes and reduce weight.

High cosmetic prototypeSimon Leggett, Director, had been recommended to come to Plunkett Associates for knowledge and advice about ‘getting things made’. Armed with an initial prototype he had made from metal, he wanted to develop an injection moulded solution and take it to production.


Plunkett Associates worked alongside Simon to provide a manufacturing solution for him. Using 2D and 3D CAD models, components were adapted and changed for improved fit and manufacturability.

Prototype high cosmetic finished partInitial prototypes were used for testing form and fit and then exhibition quality models with a high cosmetic finish were produced for marketing purposes. Photo realistic rendered images of the light were also created.

As a high performance product, material development was paramount due to the temperature extremes involved – the thermal analysis in SolidWorks Simulation was used to investigate this, and confirm heatsink performance.

Multiple manufacturing processes were used for producing the final assembly which includes clear, flexible, metal and plastic parts, the majority of which were manufactured in China by Plunkett Associates.

Virtual rendered imageManufacturing processes included aluminium extrusion, plastic extrusion, injection moulding, cnc machining, die cutting and assembly –  all managed by Plunkett Associates, giving Olivewood a delivered kit of parts at their UK site ready for final assembly.

The result – a high quality productionised product that can be easily manufactured and assembled.


“I can’t recommend Tim and his team highly enough.  We ended up with a design which can be produced and assembled quickly, efficiently and reliably, in volumes that make sense”.

Simon Leggett, Director, Olivewood Technology

See Simon’s blog here.

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  • Plunkett Associates worked on the design and production of titanium frames for an artificial heart valve where precision and consistency was paramount. Communications were efficient and productive with concepts readily incorporated into the final design, and suggestions for improvements all highly appropriate. The quality of the end product was ideal and I have no doubt that I will use the advice and expertise of Plunkett Associates again.
    David Wheatley, Wheatley Research Ltd
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    Jet Cooper, Sculptor
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    Jon Todd, Design Manager, PHS Group
  • Plunketts developed a solution that met our precision requirements at a cost significantly lower than alternative manufacturing approaches we had investigated
    Nick Skaer, CEO, Orthox Ltd
  • Plunkett Associates have excellent breadth of experience, work with high quality partners and have a flexibility that we have found enables challenges to be met successfully, cost effectively and in a timely manner.
    Nick Skaer, CEO, Orthox Ltd
  • Interestingly, people who look at it in its own right with little knowledge of what it does, just like it! It’s tactile and it looks good…
    Tim Collings, Operations Director, Troika Systems Ltd
  • To create such a consistent quality finish in chrome was an amazing achievement and the prototypes really gave our stand the wow factor.
    James Clark, Group Commercial Director, The Airdri Group
  • I can’t recommend Tim and his team highly enough. We ended up with a design which can be produced and assembled quickly, efficiently and reliably, in volumes that make sense
    Simon Leggett, Director, Olivewood Technology
  • Kirintec were thrilled with Plunketts. They made a complex process simple and we were just amazed at the lead times achieved. Plus, every single deadline was met without any drama.
    Penny While, Marketing Director, Kirintec
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    David Harden, Director, Enica Ltd
  • Thanks to Plunkett Associates flexible, bespoke and cost effective service I was able to produce the objects that I had originally had in mind.
    Simon Ryder, Artist
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    Mark Williams, Research and Development Director, Johnson Safety Products
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    Carolina Ballon-Forrester, Director, Kittyrama Ltd
  • “We use Plunkett Associates because we want someone we can trust, that knows what they’re talking about, has all the contacts, will provide reliable advice and feedback and will get the right result for us.”
    Jim Copestick. Design Manager, Thorlux Lighting
  • “Accuracy, finish and delivery all first class.”
    Andrew Peters, JMDA Ltd
  • “We were really surprised at how quickly they turned round such a high quality prototype and the parts certainly proved their worth. They were of high enough quality to provide a fantastic visual representation and to undergo rigorous testing."
    Stuart Wilson, Design Director, TRT Lighting
  • "Tim's experience, expertise and supplier base have been fundamental to us getting this project off the ground."
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  • Plunkett associates always find a solution. Whatever we need to prototype, they have a great grasp on the technologies available, costs and lead-times so we get the right solution tailored to the project needs. Have always delivered and never let us down.
    Naim Audio

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