Product Design Services

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From rough sketch to ready-for-tooling. We turn product ideas into manufacturable plastic parts - designed in Australia, with a moulder in the room from day one.

B&C Plastics is an engineering-led plastic product development partner based in Meadowbrook, just south of Brisbane. We have spent decades helping Australian businesses, inventors and OEMs take an idea, work out what it actually needs to be, and turn it into a real product on a shelf, in a workshop or in the field.

Our product design service is built around one simple principle: the people designing your part should also understand exactly how it will be tooled, moulded, assembled and recycled. That is why our industrial designers, engineers, toolmakers and moulding team all sit under the same roof.

Why this matters: most product failures are not manufacturing failures. They are design decisions made before manufacturing was ever consulted. We close that gap on day one.

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Combining full ISO certification with DISP accreditation, B&C Plastics provides high-quality, secure, and traceable plastic injection moulded components engineered for reliability and performance.

Meet the Team

  • Two men wearing green safety vests examining plastic parts in a factory setting.

    How our Brisbane product design team works

    Every project is different, but our process follows four reliable stages. You can engage us for the full journey or for a single stage - whatever the project needs.

  • 1. Concept assessment

    Have you got an idea, a sketch, a competitor product you want to improve, or a brand new category you want to invent? We start by understanding what the product needs to do, who it is for, and how it will perform in the real world.

    During concept assessment we identify your needs, your customers' needs, and the commercial constraints that will shape the project. We then translate that into a clear design brief that the wider team - yours and ours - can work to.

    •        Define the problem the product is solving

    •        Map performance, regulatory and environmental requirements

    •        Establish target volumes, price points and timing

    •        Recommend the most suitable manufacturing pathway

    •        Produce a written brief and project road map

  • 2. Project scoping

    Once the brief is agreed, we scope exactly how the project will run. Some clients want us to handle everything from concept through to packaged product. Others have an internal design team and only need our DFM, tooling and moulding capability. Both are fine.

    Project scoping is where we agree responsibilities, milestones, deliverables and the commercial model. We confirm who owns the IP at each stage, what files and reports you will receive, and how we will keep the project moving.

  • 3. Product design

    This is where the part takes shape. Our industrial designers and engineers develop concepts in CAD, model the geometry, refine the ergonomics and aesthetics, and pressure-test every decision against how the part will be made.

    Design is iterative. We use 3D printing and CNC prototyping to put real parts in real hands long before tooling is committed. Customers can hold, test, drop, fit, photograph and demonstrate working prototypes - and we can refine the design based on what we learn.

    •        Concept development and visualisation

    •        Detailed 3D CAD modelling (SolidWorks, native files supplied to you)

    •        Material recommendations including recycled and bio-based options

    •        Ergonomic, aesthetic and brand considerations

    •        Iterative prototyping at every stage

  • 4. Design for Manufacture (DFM)

    At every stage of the design phase, we consider how design choices affect manufacturing outcomes. By the time we finish, your part is genuinely ready to tool - not theoretically tool-able with a long list of compromises waiting to bite you later.

    For formal DFM sign-off we can supply mould flow analysis, finite element analysis (FEA) reports, draft angle and wall thickness checks, gate and ejector studies, and a full bill of materials. Everything you need for tooling release with confidence.

What you can hand us - and what you get back

We work with clients at every starting point.

You start with… We deliver…
A napkin sketch or rough idea Validated concept, design brief and prototype
Competitor product to improve Re-engineered design with cost, weight or performance gains
3D model from your team DFM-optimised model ready for tooling
Existing part being re-shored from offshore Fully validated local design, tooling and supply
A working prototype Production-ready design and pilot tooling

Designed for circularity from the start

Circular design is not a bolt-on at B&C - it is built into the brief. Where it makes commercial sense, we design products for disassembly and recyclability, reduce the number of polymer types in a single product, and incorporate recycled content from our own closed-loop streams.

As Associate Members of the Australian Council of Recycling (ACOR) and Partner Members of the Product Stewardship Centre of Excellence, we stay close to the policy and technology shifts that affect plastic product design - including APCO's evolving packaging targets and the Cooperative Research Centre's work on medical plastic waste.

Industries we design for

Our designers have shipped products into defence, mining and gas, plumbing and drainage, building and construction, agriculture, lifestyle and consumer goods, paint tools and trade hardware, electrical enclosures, medical and healthcare, and more. The common thread is that the products need to actually work - often in tough Australian conditions, often for years on end.

Frequently asked questions

  • No problem. A large share of our work begins with a sketch, a verbal description or a printed competitor part. Helping you take an idea and turn it into a real product is exactly what we do.

  • Yes - and we strongly recommend it for most projects. Building a tool is a serious commitment, and prototyping lets you test the market, validate the design and prove the function before tooling is cut. We can prototype as many times as needed until you are completely satisfied.

  • You do. Unless agreed otherwise in writing, the IP for any design we develop on your behalf belongs to you. We hold full DISP accreditation, which means our IP, security and confidentiality controls meet defence-grade standards. See our IP Protection page for full detail.

  • It depends on complexity. A straightforward redesign of an existing part can be a matter of weeks. A new product developed from concept through tooling is usually a 4 to 6 month journey, with prototypes in your hands much sooner. We will give you a realistic timeline as part of project scoping.

Ready to talk to an engineering-led plastics partner?

Whether you have a fully developed brief or a rough concept, the B&C Plastics team can help you scope, design, prototype, tool and manufacture in one place - right here in Australia.

  • Call us on (07) 3208 0544

  • Email enquiries through our contact page

  • Or visit our Meadowbrook facility, 20 minutes south of Brisbane

Honesty, quality and partnership - today, tomorrow and every day.