Rapid prototyping
Brandauer’s rapid prototyping services help turn early concepts into physical parts quickly, supporting faster testing and implementation. With practical manufacturing expertise behind every prototype, we help reduce development risk and move projects toward production with greater confidence.
Speed to market with prototypes built for real-world success
Brandauer has collected their knowledge of high-performance materials and fast-paced manufacturing and evolved it into a dedicated rapid prototyping service that’s efficient, dependable and built to meet the real-world demands.
What makes this service unique is the combination of advanced precision laser cutting, CNC metal forming and Brandauer’s deep knowledge of metal forming behaviours, three services you would normally have to seek out individually. This is an industry first, and no one else can offer this level of precision and turnaround time in one package.
When standard materials are in play, Brandauer can return your quote within 24 hours of the initial RFQ. Once approved, delivery of components can be completed within 48 hours of the initial order. This means you can go from concept to component in record timings – ideal for projects that demand quick decisions, live trials or accelerated product development cycles.
This service can go hand in hand with high-volume, traditional Brandauer tooling and stamping projects! Engaging with this process before committing to a fully tooled solution can give customers a chance to validate and even test their component before implementing a higher volume, precision-tooled solution.
Take a look at the full process
A look into the manufacturing capabilities
Brandauer has devised a stringent, staged journey for all customers travelling through the quick turnaround prototyping process. This process was devised to ensure everyone internally at Brandauer is able to follow the same process to ensure a rapid and repeatable service for all customers.
Technical overview of the technology
Brandauer offers multiple additional services alongside precision metal stamping, all to add value to your component to ensure the best performance at the lowest cost. Some of these services include:
Laser Cutting
Brandauer’s laser cutting machine was sourced with a precision focus in mind. This high-precision laser cutting system is designed for the use of thin-gauge metals, allowing for selected brittle materials. It is built on a granite-based precision motion platform, which ensures excellent stability and accuracy. The laser itself is a pulsed fibre laser (StarFibre P) delivering high peak power with excellent beam quality. This style of beam ensures a fast, clean cutting with minimal heat input across materials such as steel, copper, brass, titanium and nitinol.
Coupled with micron-level positioning accuracy, a high-precision cutting head with adjustable focal control, and a fully enclosed Class 1 laser safety housing. The integrated CAD/CAM Software allows for seamless integration into Brandauer’s general operations and allows for a rapid setup and efficient transition from the design phase to manufacture.
Finally, with industry 4.0 readiness, remote diagnostics and predictive maintenance all help in aiding reliable manufacturing, and if an issue were to occur, lead times would be impacted minimally.
Metal Forming
Brandauer’s no-tool metal forming capability stems from a precision CNC Metal Bending Machine which has been designed with standardised tooling to aid the manufacturing of formed components with no up-front tooling cost. The system uses a 5-axis CNC-controlled machine with program storage and USB/Ethernet connectivity to ensure fast changeover when manufacturing different components.
The machine is capable of processing sheet thicknesses from 0.05mm up to 2mm (material and geometry dependent), with a maximum bending width of around 150mm, positional accuracy of ~0.01 mm, and angular repeatability of ~0.1°. This system places itself perfectly within the Brandauer thin-gauge, precision ecosystem. This machine operates electrically, without reliance on hydraulics or pneumatics.
The patented bending process with hardened forming tools enables the reliable forming of high-strength materials up to ~1700 N/mm², including spring steels, without the need for custom tooling. Changeover is made simple with the bend angles and material thickness all adjusted via software.
Decades of experience go into every part
Whilst speed is a huge contributing factor to this service offering, what really sets this service apart from others is Brandauer’s historical dedication to precision manufacturing. By utilising this service, you are tapping into 160+ years of engineering experience. Our team understands materials, tolerances and forming techniques in a way that few others can match. Whether your design is simple or complex, we know how to produce a part that performs exactly as you need it to.
This service has been created for the people who need physical components in hand to test or even present without long lead times. The people who need physical components in hand to test, refine or present without delay. From the moment you engage with us, you will see the benefit of working with a partner that values shared knowledge, precision, reliability and responsiveness. Brandauer’s heritage as a trusted engineering supplier underpins every part we produce, even when time is short.
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Nationally recognised,
globally trusted
Beyond heritage and case studies, Brandauer has a reputation backed by a range of awards and quality standards. Along with being one of the very few SMEs to hold both the King’s and Queen’s Awards for International Trade and Innovation, the business has also been a proud recipient of multiple awards over the years, all in many different areas, spanning components, people and environmental efforts!
Beyond Brandauer’s success, we hold a range of quality certifications and are committed to continuous improvement of everything we do.
