Built around
the problem.
Not every problem has an off-the-shelf solution. Flex Systems designs and manufactures practical, purpose-built parts around the application, fitment and job they need to do.
Designed and manufactured in Rolleston, New Zealand.
One-off problems.
Practical solutions.
From custom enclosures and equipment mounts to adapters, brackets and replacement parts, we develop components where the standard option doesn’t quite work.
Practical small-to-medium components, one-off solutions and repeat small-batch supply.
Parts designed around
what you actually need.
Custom Solutions isn’t a fixed catalogue. If a standard part doesn’t fit, doesn’t exist, or could work better, we can look at the problem and develop something around the application.
Enclosures & housings
Purpose-built enclosures for electrical components, electronics, controls and other equipment where a standard box doesn’t suit.
- Electrical enclosures
- Electronics housings
- Custom cable entry layouts
- Equipment protection
Brackets & mounts
Mounting solutions designed around the equipment, available space and installation rather than forcing a generic bracket to work.
- Equipment mounts
- Sensor & camera mounts
- Accessory brackets
- Application-specific supports
Adapters & interfaces
Parts that make two things work together when their original mounting, dimensions or connection arrangement doesn’t quite line up.
- Adapter plates
- Mounting interfaces
- Retrofit solutions
- Fitment adapters
Replacement & improved parts
If a small part is unavailable, repeatedly fails or simply isn’t doing the job well, we can look at developing a practical replacement or improved version.
- Obsolete components
- Broken plastic parts
- Improved replacement designs
- Hard-to-source components
Don’t see your problem here? That’s the point of custom work. Send us a photo or description and we’ll take a look.
When the standard
solution doesn’t fit.
This installation needed a mounting arrangement that the supplied hardware couldn’t provide. Rather than compromise the installation, a purpose-built solution was developed around the application.
The problem
The available mounting hardware didn’t suit the installation location or provide the fitment needed for a clean result.
The solution
A custom mounting component was designed around the equipment, available mounting points and required installed position.
The result
A purpose-built part that integrates with the installation instead of forcing a generic mounting solution to work.
The product isn’t the starting point. The problem is.
You bring the problem.
We’ll work from there.
You don’t need a finished design or technical drawing to get started. A photo, sketch or description of the problem is often enough for an initial conversation.
Show us the problem.
Send us a photo, sketch or description and explain what isn’t working, what doesn’t fit or what you’re trying to achieve.
PHOTO · SKETCH · DESCRIPTIONDefine the requirement.
We’ll work through the important details — dimensions, fitment, mounting, environment and what the finished part actually needs to do.
FITMENT · FUNCTION · REQUIREMENTSDesign & build.
A practical solution is developed around the application and manufactured into a finished part ready to be put to work.
DESIGN · MANUFACTURE · SUPPLYRefine & retain.
Where required, the design can be refined from real-world feedback. Once proven, it can be retained for straightforward future supply.
REFINE · VALIDATE · REPEATYou don’t need to know what the solution is. Tell us what the problem is and what you need the finished part to achieve.
Built for the jobs where
custom makes sense.
Flex Systems focuses on practical small-to-medium components, one-off solutions and repeat small-batch supply. That makes us particularly well suited to problems where an off-the-shelf part isn’t quite right, or simply doesn’t exist.
This is where we work best.
One-off solutions
A specific problem that needs a purpose-built part rather than something selected from a catalogue.
Small-batch production
Low-volume parts for builders, workshops, businesses and repeat applications.
Small-to-medium components
Individual parts up to approximately 270 × 270 × 250 mm, depending on geometry, orientation and the application.
Parts that need improving
Existing components that don’t quite fit, repeatedly fail or could be redesigned to work better.
Some jobs need a different process.
Large-scale components
Large fabricated or oversized products are generally better suited to other manufacturing methods.
High-volume mass production
Flex Systems is focused on one-off and small-batch supply rather than large-scale production runs.
Safety-critical components
Structural, braking, coupling, suspension and other safety-critical applications are outside our custom scope.
Specialist regulated parts
Applications requiring specialist certification, regulated materials or controlled manufacturing processes may require a specialist supplier.
A practical guide to our current individual-part manufacturing envelope. Larger overall solutions may still be possible where the design can sensibly use multiple components.
Materials are selected around the intended use and requirements of the part. PETG is our primary rigid production material, with flexible TPU used where the application requires flexibility, sealing or cushioning.
You don’t need to specify the material. Tell us what the part needs to do and where it will be used — material selection forms part of developing the solution.
Got something that
needs a better solution?
Send us a photo, sketch or description of the problem and tell us what you’re trying to achieve. You don’t need a finished design — that’s where we come in.
A photo or sketch of the problem
What you need the part to do
Any useful dimensions or fitment details