Custom Rotational Moulding Services

Gaybo Limited offers extensive experience and the ability to support your project. We bring five decades of experience in processing, design, development, and testing to the table, enabling our team to support you and your project successfully.

Who Are We?

We started manufacturing in 1968 and built an exceptional reputation for our Gaybo Limited GRP and composite kayaks. Now our speciality lies in over 30 years of high-quality roto moulding for the water sports industry.

• Globally Renowned Brands: We produce kayaks for our own globally renowned Wave Sport brand and manufacture and distribute Perception kayaks for the European market.
• Global Marine Leaders: In addition to our own brand activities, we produce sailing dinghies for global leading brands, Topper and Fusion.
• Diverse Technical Portfolios: Other projects have included hovercraft, playground equipment, assorted boats, and we are especially proud to have worked with Sir Ranulph Fiennes on polar sledge projects.

Our experience in producing for unforgiving and demanding applications and environments makes us ideally placed to assist with technical contract moulding projects of all types.

Rotational Moulding Projects

The team will focus on your specific needs. We will work from your concept or existing design to support your project with initial design considerations to guide CAD modelling and ensure a mouldable product. Throughout the process, we collaborate with specialist partners to support our design expertise through 3D CAD, prototyping, and final tooling.

Tooling

We work closely with proven toolmakers to create process-appropriate tooling that moulds a product to meet our exacting standards and high expectations. If tooling were not considered good enough for our own brand product, we would not expect you to accept it either.

• Tooling Formats: We most frequently work with cast aluminium or CNC-machined aluminium billet.
• Complex Arrangements: A large number of our products have moulded-in features and components that require specialised mould design and complex arrangements. Our team will help and advise you on the best tooling approach for your product.

Production Workflow

Once in production, we follow a proven pre-production sampling process until you are ready to sign off on full production. In production, we follow a quality-control and continuous-development process to ensure your product is the best it can be.

Production Capability

We specialise in larger format products with a technical focus, although we also mould our own component parts in-house. Our three rotational moulding machines offer good scope for both small and large moulding projects.

*Optimized Fleet Routing: We select the most appropriate machine for a project based on mould dimensions, complexity, cycle profile and energy efficiency.

Materials & Constructions

Material demands vary from project to project, depending on the product's application. Drawing on our experience and working with industry-leading material suppliers, we can ensure you are confident that we are selecting the right material for the job.

We have extensive experience and expertise in single and multi-layer production across a variety of polyethylene grades, with a strong focus on high-end HDPE materials. Polyethylene is by far the most widely used material for rotational moulding. While we focus predominantly on HDPEs we have extensive experience moulding different grades of polyethylene in both single-layer and multi-layer constructions:

Single-Layer Construction

Appropriate for a wide variety of applications. It offers the most robust construction because it provides the thickest possible cross-section of the structural wear layer. This is the most widely used method for manufacturing kayaks and many of the roto moulded items you see around you.

Three-Layer Foam Core Construction

Popular in applications where product stiffness is the primary consideration. The inclusion of a PE foam core provides greater stiffness than non-foaming materials. This foam core is encapsulated by inner and outer layers of PE/HDPE to protect the foam from wear and water absorption.

Post Mould Assembly

Beyond the moulding stage of the manufacturing cycle we have the capability to offer a full outfitting service for many products. Our own kayak ranges, for example, are supplied ready for the water with a wide array of features and componentry to ensure our products are best in class and completed to the highest possible standards. These same standards are applied to every item or product we supply, earning us a reputation as a true market leader.