How It's Made
Inside the Factory
Our UK-based factory has the potential to divert over 3000 tonnes of plastic waste annually, producing over 300 3m x 1.2m Smile Plastics boards each week, and converting almost 70 tonnes of 100% recycled material every seven days.
SMILE PLASTICS
Supersized Panels
At our factory in Wales, UK, a skilled team of local craftspeople hand-arrange and press each recycled plastic panel to create one-off statement pieces for your commercial projects.
Each recycled plastic sheet starts as a supersized 3000 x 1200mm with an unfinished edge, making them extremely versatile for all types of commercial projects. Every piece of the board can be put to use, ensuring nothing goes to waste. And when the panels reach the end of their life, they can be repurposed or recycled – closing the loop on plastics.
Raw Materials
Our Smile Plastics panels are made from 100% recycled/recyclable plastic, sourced from a mix of pre- and post-consumer waste. From yoghurt pots to white goods, we collect materials that would otherwise go to landfill. Each batch is selected for quality and character before being transformed through our unique manufacturing process.
Sorting and Mixing
Every batch we make up will be a little different from the previous. Ultimately, everything’s at the mercy of the method. We can influence sheet production to a certain extent but the process will always win. There’s always an unexpected element. It’s one of the reasons the raw material makes each sheet unique.
Pressing
There’s no need for additional finishing as our proprietary process ensures each panel comes off the press complete, with its surface pattern, durability, and character already formed.
Research and Development
At Smile, innovation and sustainability go hand in hand. We continually refine our manufacturing to be more efficient, sustainable, and high-quality. From cutting energy use to recycling all production waste in-house. Beyond plastics, we’re exploring new waste streams that have the potential for fresh life in commercial interiors. Our bespoke materials projects with leading brands open up new possibilities of colour, pattern, and materiality, and we thrive on how clients push us to meet creative ambitions as well as practical needs.
Cutting and Finishing
Our panels can be cut and finished using standard workshop tools – from CNC routing to hand-finishing techniques. While each sheet comes off the press ready for use, we recognise that every project has its own unique demands. That’s why we offer guidance on working with our materials, ensuring clean cuts, smooth edges and the best possible finish.
Solid and consistent
Offering durability and longevity over time
Waterproof
For healthier interior environments
Customisable
Materials that flex to fit your creative vision
Moderate scratch resistance
Created to be useful. Finished to last