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 customising IKEA’s Metod, Pax, and Platsa cabinets with high-quality plywood doors, drawer fronts and worktops.
Offering a seamless process for homeowners and professionals to tap into a unique blend of affordability, sustainability and design led craftsmanship to elevate their kitchens and wardrobes, Plykea combines IKEA’s functionality with bespoke design elements, delivering a handcrafted, design-led aesthetic at a fraction of the cost. From its East London workshop, the varied client base includes not just homeowners but B2Bs made up of architects, contractors and interior designers emphasising precision, quality and sustainability.
To achieve this level of precision and scalability, Plykea turned to AXYZ routers, a pivotal decision that has defined its success.
In its early days, Plykea relied on outsourcing to meet production demands. However, as demand grew, it became evident that external manufacturing limited the company’s ability to maintain consistent quality, meet customisation requests and scale operations. The company needed a solution that would enable in-house manufacturing to maintain the quality and precision critical to its offerings. With a growing customer base and increasing demand for its custom plywood fronts, Plykea required advanced technology to streamline production while ensuring consistency and quality. The result would: ensure precision in cutting and customisation; maintain high-quality finishes that align with Plykea’s bespoke offerings; and increase production efficiency while reducing reliance on external manufacturers.
Plykea brought production in-house in 2018 with its first CNC router. When asked why they changed: “Initially, the machine required manual tool changes which restricted efficiency”, said Ben Price, production manager at Plykea. Recognising the need for advanced automation, Plykea upgraded to the AXYZ INFINITE CNC router, featuring automatic tool-changing capabilities and advanced features tailored to Plykea’s needs. This investment transformed their production process.
The INFINITE router is a highly configurable CNC machine that is suitable for one-off, small batch production as well as high volume and high productivity applications, including woodworking, plastic fabrication, engineering plastic machining and so much more. For a wide range of routing operations, one can choose from high-speed spindles ranging from 5 HP to 15 HP. For knife cutting, choose from a tangential knife, which can be used for creasing and folding applications or an oscillating knife which can be used to process soft goods material.
When asked why Plykea chose AXYZ Ben explained the following: “The INFINTE router is compact and reliable: AXYZ routers fit seamlessly into Plykea’s workshop, making them an ideal choice for the space constraints. Cost-Effectiveness: AXYZ routers deliver high performance within budget, eliminating the need for expensive outsourcing.
“Durability and Precision: Built to last, AXYZ machines offer the reliability Plykea needs for daily production while achieving the exacting standards of the custom designs.”
AXYZ routers handle the precise cutting of Plykea’s signature plywood fronts, ensuring seamless alignment with IKEA hardware with precise placement of hinge holes and fixings. The machine also supports the company’s ability to accommodate custom sizes, from non-standard door dimensions to bespoke worktops and modular shelving units.
The automatic tool-changing capability of the AXYZ INFINITE drastically reduced setup time and eliminated manual errors. This automation not only enhanced productivity but also allowed the team to focus on design and innovation.
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. Over time, the optimised machine settings further minimised material waste, contributing to Plykea’s profitability.
By tailoring the machine’s settings to its materials AXYZ routers provided consistent, high quality finishes to Plykea’s premium materials, such as birch plywood with veneers of oak, walnut or ash. The machine’s precision enabled cleaner cuts and superior results, enhancing Plykea’s reputation for excellence.
With AXYZ routers managing core production tasks, Plykea had more resources to innovate, such as introducing Ürtil modular shelving units and custom pantry designs.
“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 comprehensive support, including prompt troubleshooting guidance and on-site assistance, ensuring a smooth transition allowing Plykea to fully leverage the machine’s capabilities”, said Ben. “The introduction of automation has been a positive experience for Plykea’s team. They affectionately named the AXYZ INFINITE router ‘Greg’,” he continued, underscoring its integration as a vital member of the Plykea family. Employees welcomed the efficiency and precision automation brought to their workflow, viewing it as an opportunity to focus on craftsmanship and innovation. Automation has also enhanced job satisfaction by streamlining workflows and providing opportunities for advanced CNC training.
Plykea ensures smooth operation with a strict maintenance schedule, including daily cleaning, internal cleaning schedule and an annual service for “Greg.” This proactive approach minimises downtime, ensuring uninterrupted production and keeping the machine running at peak efficiency.
Plykea’s success with AXYZ technology has set the stage for future growth. Looking ahead, Plykea plans to expand production capabilities and therefore aims to add another AXYZ CNC router to meet increasing demand. This addition will enable Plykea to scale its operations while still maintaining the precision and quality its customers expect.
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.
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.
See page 26-27 of our April/May 2025 issue on our Back Issues page.
