Formation Plastics, founded in 1995, is a multi-award-winning UK fabrication company.

Bespoke Fabrication Specialists of the Year 2022/23, 2024/25, and 2026/27.

Through FP Technologies, we bring decades of industrial engineering experience into inland waterways applications.

We specialise in CNC machining, CAD/CAM design, high-precision plastic welding, and complex structural fabrication, all carried out in-house. Our work spans HDPE, acrylic, polycarbonate, foam PVC, and aluminium composite, forming the foundation of our canal boat shell manufacturing capability.

We use Röchling Polystone® G, a premium industrial-grade HDPE proven in demanding marine environments worldwide. Röchling, founded in 1822, brings nearly two centuries of engineering expertise, with materials used in Arctic workboats, ferries, rescue craft, aquaculture vessels, and industrial marine systems operating successfully since the 1980s.

HDPE delivers corrosion-free performance with no rust, no pitting, and no need for repainting cycles. It provides strong thermal stability, helping maintain more consistent internal temperatures and improving onboard comfort.

Its lightweight structure improves handling in locks, reduces energy demand, and enhances manoeuvrability. Unlike rigid materials, HDPE absorbs impact energy rather than transferring it, reducing damage to both the vessel and canal infrastructure.

Our hulls are engineered as a structural system rather than a traditional shell.

Each hull begins with a CNC cut rib framework forming the structural backbone. Interlocking HDPE panels are then integrated and fully welded into a continuous bonded hull with long-term strength and integrity.

The system is designed for controlled flexibility, impact absorption in locks, and long-term durability without corrosion or fatigue. We supply hull shells only, allowing full freedom for bespoke interior fit-outs.