Octopus Energy is the UK’s largest and most awarded energy supplier. Since launching in 2015, the company has built its reputation on smart, customer-first innovation and its Cosy heat pump range is a clear example of that.
Today, Octopus Energy serves millions of homes across the UK, with a mission to make clean, affordable heating the norm rather than the exception.
Cosy comes in three sizes: Cosy 6, Cosy 9 and Cosy 12. Designed, built and installed by Octopus’s own team, Cosy can be up to 4x more efficient than a gas boiler. The outdoor unit, where the fan grille sits, is engineered to run efficiently even in cold weather using the natural refrigerant R290, which is kinder to the environment than many older alternatives.
The Challenge
Octopus Energy required a plastics manufacturing partner capable of producing a large fan grille, with a complex shape, that would:
- Require high-complexity tooling to achieve the intricate geometry involved
- Fill correctly across sections ranging from thick to thin
- Hold tight control over warping and dimensional stability on a large component
- Be robust, reliable, and suitable for permanent outdoor use, in all weathers
The project required tight tolerance control, careful material selection, and proven quality systems suited to a component that would sit outside a customer’s home for years.
How Key Plastics Responded
Key Plastics worked closely with the Octopus Energy team from early development through to full production. The project included:
Design & Tooling
Key Plastics designed and manufactured custom injection mould tools to achieve high dimensional accuracy, using materials selected for the application and for long-term outdoor exposure.
Production & Quality Assurance
Every part was manufactured using validated processes, with ongoing inspection and process monitoring to ensure it met specification.
Weatherproof Fan Grilles Delivered
Key Plastics supplied fan grilles built for a reliable fit, weather-resistant outdoor durability, and quiet, smooth airflow.
Impact & Outcome
Dependable Production
A dependable supply of precision-moulded components, ensuring confidence and reliability.
Ongoing Support
Support for the continued rollout of the Cosy heat pump range.
Aligned Partnership
A manufacturing partnership aligned with the requirements of the home energy and heating technology sector.
A Few Words From Octopus Energy
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“Key Plastics have been a brilliant manufacturing partner for our Cosy fan grille. They understood the complexity of the part from day one, and delivered tooling and production that met our tolerances and durability requirements on time, every time. As we’ve scaled the Cosy range, their support has stayed consistent — precise, reliable and easy to work with.”
