Linecross

Linecross, thermoplastic and polyurethane moulding for automotive and industry

Linecross presents itself as the UK's largest independent vacuum forming company and one of Europe's leading manufacturers of polymer and polyurethane composite products. The company has over 50 years of experience in sectors such as premium automotive, leisure and off-highway machinery.

Its activity ranges from design and engineering to series production, with the capacity to manage complex tooling programmes and sequenced supply. The company defines itself as a tier 1 and tier 2 supplier to prestigious brands, and serves both major automotive OEMs and niche vehicle manufacturers.

Manufacturing processes

Linecross structures its offering around six main processes:

• Vacuum forming: gives three-dimensional shape to extruded thermoplastic materials.
• Injection moulding: optimal process for high-volume plastic components.
• Polyurethane systems: used in applications where comfort and support are essential.
• Compression moulding: for complex, high-strength parts with optimised cycle times.
• Assembly and sequenced supply: includes techniques such as structural adhesives and ultrasonic welding.
• Waterjet and CNC trimming: precise trimming and cutting of excess material from parts and components.

From concept to production

Linecross's in-house design and engineering team works alongside the customer to take their concepts into production. The company offers a complete service covering design feasibility studies, production tooling and component supply. Its project managers, supported by multidisciplinary teams, coordinate complex tooling programmes —typically more than 250 tools per year— from prototyping to production.

The process is organised into four phases: concept, optimisation, prototype and production. In the concept phase, design feasibility is assessed; in the optimisation phase, knowledge of materials and processes is used to make the product fit for purpose; the prototype phase includes 3D printing and pre-series tooling in ureol and aluminium; and production manages thousands of parts and complex assemblies through sequenced supply and MRP systems for just-in-time components.

The technical managers for each discipline —vacuum forming, injection, compression and polyurethane moulding— advise on initial material selection, tool design and overseas trial support before introducing projects into the manufacturing plants.

Sectors it serves

Linecross organises its activity into four markets:

• Automotive: manufactures interior and exterior components for global luxury and sports car manufacturers.
• Leisure: offers a complete turnkey solution from design to materials advice, adapted to the pace of this sector.
• Off-highway: manufactures and designs agricultural and construction components for demanding environments.
• Speciality: bespoke development and solving technical challenges in niche and emerging markets.

Facilities and presence

The Linecross Group has three manufacturing facilities located centrally in England, between the East Midlands and West Midlands regions. The company describes them as world-class facilities. The plants are Linecross Rutland, in South Luffenham (Rutland); Linecross Composites, in Cannock (Staffordshire); and Linecross Corby.

History

The company was founded in 1967. In 1993 it was acquired by Maple Holdings; in 2003 there was a management buyout (MBO) by the current management team; in 2013 it acquired BI Composites; and in 2023 it began a period of continuous expansion and growth. In 2025 it opened the Corby plant.

Certifications and environmental management

Linecross states that it holds ISO 45001:2018 (occupational health and safety), ISO 14001:2015 (environmental management), ISO 9001:2015 (quality management) and IATF 16949:2016 (quality for the automotive sector) certifications at its Rutland and Composites plants. The company also publishes documents such as a supplier code of conduct, a gender pay gap report, a health and safety policy, a goods receiving and despatch protocol, a carbon management plan, an environmental policy and a sustainability manifesto.

The company states that sustainability is a priority and that it applies rigorous recycling of by-products and waste, as well as managing chemicals responsibly. Its environmental management system is geared towards continuous improvement.

Headquarters and locations

Linecross Rutland site: Station Road | South Luffenham | Rutland | LE15 8NG

Linecross Composites site: Green Lane | Bridgtown | Cannock Staffordshire | WS11 0JW