Crafting perfection: Plykea’s custom kitchen designs powered by AXYZ

 Founded in 2016 by two friends seeking an affordable yet high-quality solution for customising IKEA kitchen and wardrobe cabinets, Plykea has revolutionised bespoke design by enhancing IKEA’s Metod, Pax and Platsa cabinets with superior plywood doors, drawer fronts and worktops. Offering homeowners and professionals a seamless process that blends affordability, sustainability and craftsmanship, Plykea combines IKEA’s functionality with bespoke design elements, delivering a handcrafted, design-led aesthetic at a fraction of the cost.

Operating from its East London workshop, Plykea serves a diverse client base, including homeowners as well as B2B clients such as architects, contractors and interior designers. To achieve the precision and scalability needed for its operations, Plykea turned to AXYZ routers – a pivotal decision that’s defined its success.

The challenge: scaling precision & quality

In its infancy, Plykea relied on outsourcing to meet production demands. However, as demand grew, external manufacturing limited the company’s ability to maintain consistent quality, meet customisation requests and scale operations efficiently. To address these challenges, Plykea sought an in-house manufacturing solution that would: 

• Ensure precision in cutting and customisation;

• Maintain high-quality finishes aligned with Plykea’s bespoke offerings;

• Increase production efficiency while reducing reliance on external manufacturers.

The solution – adopting AXYZ routers

Plykea brought production in-house in 2018 with its first CNC router. Initially, the machine required manual tool changes, which restricted efficiency. Recognising the need for advanced automation, Plykea upgraded to the AXYZ INFINITE CNC router, featuring automatic tool-changing capabilities and advanced features tailored to its needs. This investment transformed their production process.

The AXYZ INFINITE router is a highly configurable CNC machine suitable for both small-batch and high-volume production. It supports various applications, including woodworking, plastic fabrication and engineering plastic machining. For routing operations, users can choose from high-speed spindles ranging from 5HP to 15HP, while knife-cutting options include tangential and oscillating options for precise cutting of soft goods materials.

When asked why Plykea chose AXYZ, Production Manager Ben Price highlighted the INFINITE router’s many benefits:

• Compact and reliable – AXYZ routers fit seamlessly into Plykea’s workshop, making them ideal for space-constrained environments.

• Cost-effectiveness – AXYZ routers delivered high performance within budget, eliminating the need for expensive outsourcing.

• Durability and precision – built to last, AXYZ machines offered the reliability Plykea needed for daily production while maintaining exacting standards.

How AXYZ machines transformed Plykea’s operations:

Precision & customisation

AXYZ routers enable precise cutting of Plykea’s signature plywood fronts, ensuring seamless alignment with IKEA hardware, including the exact placement of hinge holes and fixings. The machines also support non-standard door dimensions, bespoke worktops and modular shelving units, allowing Plykea to accommodate a wide range of customisation requests.

Efficiency gains

The automatic tool-changing capability of the AXYZ INFINITE router drastically reduced setup time and eliminated manual errors. This automation enhanced productivity, allowing the team to focus on design and innovation.

Cost savings & profitability

By bringing production in-house, Plykea eliminated outsourcing costs and external markups. This move not only reduced expenses, but also provided the flexibility to scale efficiently. Optimised machine settings further minimised material waste, thus enhancing profitability.

Enhanced product quality

By tailoring the machine’s settings to its materials, AXYZ routers provided consistent, high-quality finishes for Plykea’s premium materials, such as birch plywood with oak, walnut or ash veneers. The machine’s precision enabled cleaner cuts and superior results, strengthening Plykea’s reputation for excellence.

Increased capacity for innovation

With AXYZ routers managing core production tasks, Plykea had more resources to innovate, introducing new product lines such as Ürtil modular shelving units and custom pantry designs.

Overcoming challenges with AXYZ

“Integrating advanced CNC technology posed initial challenges, such as learning new workflows and optimising the router for specific materials. However, AXYZ’s technical team provided exceptional support, including troubleshooting guidance and on-site assistance, ensuring a smooth transition and allowing us to fully leverage the machine’s capabilities,” Ben explained.

Employee engagement

“The introduction of automation has been a positive experience for our team. They even affectionately named the AXYZ INFINITE router ‘Greg,’” Ben shared, highlighting the machine’s integration as a vital part of the Plykea family. Employees welcomed the efficiency and precision it brought to their workflow, seeing it as an opportunity to focus on craftsmanship and innovation. Additionally, automation has enhanced job satisfaction by streamlining processes and providing opportunities for advanced CNC training.

Maintenance & reliability

Plykea ensures smooth operation through a strict maintenance schedule, including daily cleaning, internal inspections and an annual service for ‘Greg’. This proactive approach minimises downtime, ensuring uninterrupted production and keeping the machine running at peak efficiency.

Future plans

Plykea’s success with AXYZ technology has set the stage for future growth. Looking ahead, the company plans to expand its production capabilities by adding another AXYZ CNC router to meet increasing demand. This addition will enable Plykea to scale operations while maintaining the precision and quality expected by customers.

Conclusion: results & benefits

Plykea’s partnership with AXYZ routers exemplifies the power of automation in modern manufacturing. By embracing AXYZ’s cutting-edge technology, Plykea has maintained its commitment to craftsmanship while scaling operations to meet growing demand. With its dedication to quality, sustainability and innovation, Plykea continues to transform the way kitchens and wardrobes are designed, proving that bespoke design can be both functional and beautiful.

Results & benefits

• Improved productivity – automated processes reduced setup time and increased output.

• Higher Profit margins – cost savings from in-house production enhanced profitability.

• Unmatched quality – the precision of AXYZ routers allowed Plykea to deliver premium products consistently.

• Customer satisfaction – the seamless integration of custom fronts with IKEA systems delighted both homeowners and industry professionals.

Plykea has achieved unparalleled precision, efficiency and quality, solidifying its position as a leader in bespoke kitchen and wardrobe design. With its commitment to sustainability and innovation, Plykea is poised – with the help of AXYZ machines – for continued growth and success.

For further information on the AXYZ range of routers, call 01952 291 600 or visit www.axyz.com. For more details on Plykea, see www.plykea.com.