Polystyrene Converting

Transforming stock materials into useful, high-performance and lightweight parts that fit perfectly and add value to your production process. Polystyrene cut to size by professionals.

A broad range of processing techniques

Whether you need components for insulation, sculptural displays, bespoke packaging or industrial applications, we’re highly experienced in working with all grades and densities of polystyrene for a wide variety of use cases. You can rely on us to have polystyrene cut to size to meet your specific needs.

Any project begins with understanding your end goal. We’ll then take your designs or technical drawings and turn them into accurate, production-ready parts.

We cover the full spectrum of converting processes, which you can learn more about below. Or if you’re looking specifically for insulation, please click here.

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Which polystyrene is right for you?

EPS is lightweight, versatile and cost-effective. It is well-suited to applications where weight, adaptability and ease of conversion are key. It’s commonly used for lightweight structural shapes, packaging inserts and civil engineering applications.

XPS is denser, stronger and has a finer structure than EPS. It is well-suited to applications where improved mechanical performance, moisture resistance and surface finish are required. It’s commonly used for precision-cut insulation components, applications with tighter tolerances and environments where durability matters.

We recycle any surplus or offcut EPS polystyrene in-house, compacting it at 40:1 ratio for efficient storage and transportation to specialist facilities, where it is 100% recycled into new products.

Our processing techniques

Computer-controlled hot wire cutting

When you need clean, accurate profiles that stay consistent from the first part to the last, hot wire cutting delivers. We use it to carry out custom polystyrene cutting to quickly and efficiently shape EPS and XPS, helping you achieve reliable results without unnecessary waste or variation.

Our processing techniques

CNC routing and milling

If your project calls for more detail, tighter tolerances or complex 3D forms, CNC routing and milling give you the control you need. We use this process to produce precise features, compound curves and profiles that fit exactly as intended.

Our processing techniques

Polyurea hard-coating

For protection, durability and performance, polyurethane spraying allows us to apply a rigid coating over polystyrene to add a tough, impervious and robust surface, suitable for handling, overpainting and exterior use.

Our processing techniques

Hand-finishing and sculpting

Some designs simply cannot be finished by machine alone. Where your project demands complex contours or a more refined finish, our artisans hand-finish and sculpt to achieve the shape and detailing you require.

Our processing techniques

Assembly and collating

To save you time and simplify delivery, we can assemble and prepare parts before they leave our facility. By handling assembly and collation in-house, we deliver components that arrive ready to install or use straight away.

Why choose
Perudo?

We think beyond the drawing

You come to us with specifications or concepts. We look at how your component will actually be used, installed and scaled, helping you avoid issues before production begins.

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We take ownership

Your project is handled by a dedicated, experienced team who take responsibility from start to finish. That means clearer communication, fewer surprises and a partner who is invested in getting it right.

Explore our ethos

Built for repeatability

Whether it is a one-off or ongoing supply, our processes are designed for consistent output and reliable lead times. You get production you can plan around.

Our process

Everything in-house

From processing and production through to collation and dispatch, we do it all under one roof. That keeps quality high and turnaround times tight.

Our manufacturing services

Trusted across manufacturing and creative industries

Our experience spans precision manufacturing and complex creative builds. You benefit from practical problem-solving backed by technical rigour.

See our work

Our
Applications

Manufacturing for any industry

We support a wide range of industries, delivering precision polystyrene components and bespoke solutions for both industrial and creative applications.

Industrial Manufacturing Client

“Thank you for your continued excellent service over the past few years. You have always gone out of your way to help us when we have had an urgent order or a problem (which is extremely rare)!“

Mark – Engineering Buyer

Construction Client

“We were blown away by the quality of the product you have produced. Congratulations and thank you from all from us here.“

Bryan – Sales Manager

Building Products & HVAC Client

“You are the only supplier that I do not worry about, deliveries come in on or ahead of schedule. I wish all my suppliers were like you.”

Andy – Chief Designer

Our manufacturing process

Think. Plan. Prototype. Develop. Deliver

We’ll become your manufacturing partners, advising you on design practicalities and supporting you every step of the way. 

01

Think

Our discovery process helps us understand what you need and why you need it. 

02

Plan

Here’s where we work out any issues, working with you to decide how we’ll bring your designs to life. 

03

Prototype

If required, we’ll create a sample, allowing you to see the physical product before we go into production. 

04

Develop

Production begins; we’ll keep you in the loop at all times. 

05

Deliver

Feedback is incredibly important to us. Here, we work with you to iterate on future projects together. 

Have a requirement? We’re here to help

Our creative services

Need something a little more special? Our creative team are here to help. 

We can craft and finish any project you desire, whether that’s creating lightweight props, oversized models, sculptural features, sceneography, hero pieces and much more. We can help. 

Take a look at some of our creative projects here:

Creative services