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Introduction to precision prototyping solutions
Since 1862, Brandauer has been recognised for its precision-engineered metal components, supplying demanding industries across the world. Historically, the company’s focus lay in medium to high-volume production, where efficiency and repeatability are critical.
However, early-stage product development often requires a different approach, one that requires speed, flexibility and adaptability over scale.
Whilst we have our Special Products Division for low to medium volume production runs, we didn’t have a solution for fast turnaround precision prototypes. That’s where the idea, investment in and implementation of the precision laser cutting and metal forming division came from.
But what is this division, and why are we so excited about it?
To put it simply, it removes the hurdle of initial tooling costs and associated extended lead times, allowing us to deliver precision prototypes or low-volume manufacturing runs quickly and cost-effectively. Now, we can extend that same precision Brandauer is famous for, to early-stage development and low-volume projects.
Positioning Brandauer as a true precision engineering partner that can take you from the very first stage right the way through to full-high volume production. Whether that’s through trial designs, testing new product ideas, or even produce limited batches without committing to large-scale tooling and automation investments.
And for Brandauer, it deepens our offerings to customers as an all-in-one precision-engineering partner. We can now help clients refine their designs, validate every detail, and build total confidence before moving to full-volume production. Whether you’re an established manufacturer looking for initial validation or a startup that’s just at the beginning of their journey. Precision laser cutting and metal forming will have a place in your engineering business.
Development and collaboration
The configuration of our laser cutting system wasn’t completed alone. For this project, we teamed up with an academic collaborator, University of Birmingham. With the objective of identifying a system capable of processing multiple material types with thickness ranging up to 2.0mm, all whilst keeping up our micron level accuracy standards, we worked with them to develop a machine selection strategy.
Following market evaluation, five shortlisted machines were benchmarked against eight criteria, including tolerance precision, cut quality, edge burn, burr formation, cutting area and more. This assessment determined the optimal configuration on offer and the best all round solution for our customers.
The investment was also supported by a 40% innovation grant from the Aerospace UP (AUP) programme, recognising the project’s contribution to advanced manufacturing capability within the region. This funding, along with supplier collaboration and academic input, was integral to bringing the system to operational readiness.
Deep dive into precision laser cutting
Features and benefits of Brandauer’s precision laser cutting
- A compact laser, fine cutting system for processing thin and thick metals and alloys, from 0.1mm to 2mm thickness
- Positioning accuracy of <0.005µ
- High-precision granite motion module and powered by the latest 1.5kW fibre laser technology
- Power CAD/CAM operating software for quick setup
- Industry 4.0 and lIoT ready
- Powered by reliable fibre laser technology
- Class 1 laser housing meets the highest ergonomic standards
- Large working chamber and pneumatic lifting floor
- Quick setup due to powerful CAD/CAM software
- Working area of 400x500mm for focus on micro precision sized blanks
This system has enabled Brandauer for rapid reconfiguration between jobs and minimal setup times, meaning not only fast manufacturing, but minimal downtimes, all contributing to lower costs incurred by you, the customer.
Deep dive into precision metal forming
Brandauer can now laser cut precision flat blanks across a range of materials and thicknesses that are ideally fit for purpose, but what about formed components?
This was another pain point for Brandauer and our clients, and we quickly realised that if we could implement a solution which allowed for formed components, with the criteria we set out for the laser cutting solution, we’d be onto a model that could provide huge value add to a range of potential and current customers.
We then went through similar tests, ensuring the machine we selected to complete the task at hand had precision in mind. For Brandauer, the investing in our precision metal forming machine was a strategic move, ensuring the complete offering of fast turnaround precision prototyping.
Features and benefits of precision metal forming
- Standard tooling for minimal initial setup cost (no hard tooling to manufacture)
- A compact and programmable servo-driven machine for precision bending requirements
- Cost-effective production from one-off prototypes up to middle series volumes.
- Offer a capacity of up to 150mm bending widths and a max. of 2.0mm thickness for smaller geometries.
- Including powerful operating software for quick setup
- Plug and play standard metal forming dies on the shelf
- Quick change over of standard tooling
An end-to-end prototyping solution
With the purchase of these two machines, Brandauer isn’t just offering a single-stage process; it’s a complete, end-to-end precision prototyping solution. By combining precision laser cutting with advanced metal forming, we can deliver fully functional prototypes that are ready for real-world testing.
Another unique feature of this service is that it sits within the wider Brandauer ecosystem. That means customers benefit from our established design, consultancy, and production expertise, removing the need to outsource different stages of their manufacturing journey.
Why do businesses choose this approach?
- No tooling cost – Our metal forming machine forms parts with the use of standard tooling, meaning there is no up-front cost for you to initially manufacture the part!
- Fast turnaround – With stocked materials, Brandauer can manufacture and ship the parts to you in as little as 48 hours! (more on this later)
- Simple, quick design changes – Because the manufacturing process is quick and repeatable, if we manufacture components to your drawing for you and they turn out to be not fit for purpose, Brandauer can re-design and re-manufacture the updated revision of your component without having to re-invest large amounts of your capital into modified tooling.
- Project validation – Before taking your product to a high-volume production run (which requires significant capital investment), laser cutting and forming your part through our precision prototyping service will allow you to validate your part before taking it to scale. This will give you and your team 100% confidence at the lowest possible cost.
- Continuous low-volume production – Throughout this article, we have spoken a lot about how this service is fantastic for the infancy stages of your project’s lifecycle. But this solution can also aid people who are just looking for a low-volume run of their parts, where progression stamping with a dedicated tool just isn’t cost-efficient.
It’s not just about manufacturing parts at Brandauer anymore; it’s about enabling innovation internally for our customers. This means we can work with customers who are either manufacturing-ready, with a full finished drawing, or just an initial sketched idea.
We can offer you support that goes beyond a finished component. You gain the ability to test, learn and refine.
Once validated, the path forward is flexible. Continue with low volume production or scale up into high-volume stamping with full tooling and developmental support. Either way, Brandauer remains your partner throughout.
A fast-turnaround solution for prototype parts
We know that time is often the most valuable resource in any project, especially when taking an innovation to market. That’s why our laser cutting and metal forming solution has speed built into its functionality.
By removing bespoke tooling from the equation, the turnaround time for the components will be reduced massively. So much so, Brandauer can now commit to a 48-hour turnaround from initial enquiry to dispatch to the customer. For teams with simple component design and stocked Brandauer materials, this expansion can transform the pace of development within your project. Helping get new ideas off drawings and into the engineers’ hands close to immediately.
Of course, not every project is straightforward and the engineers at Brandauer can understand this. Sometimes, components need to be complex or require the use of difficult to work with materials, and naturally, these projects are going to yield longer lead times. But even so, Brandauer can guarantee shorter lead times compared to industry standard, tooled methods of manufacturing. The agility, regardless of the project complexity, helps you validate concepts quickly, adapt designs without costly delays, and bring innovation to market at a pace that matches today’s demanding timelines.
Prototype to production and Brandauer’s engineering consulting – a lifetime partner
We know that taking on a large-scale engineering project can feel overwhelming. It’s not just the cost, but also the pressure to make the right decisions at all stages of the project. We recommend that all customers validate their components before the full production investment takes place. As mentioned before, with a fraction of the setup cost required, you can use our precision prototyping service to test and refine your design, giving you peace of mind before making that big commitment.
Further from part validation, this service sets itself apart through the depth of expertise behind it. We act as an extension of your team. By addressing Design For Manufacturing (DFM) challenges early, running tests on prototype components, validating functionality of the design and making necessary drawings and CAD changes. We help all businesses accelerate their development cycle while avoiding costly pitfalls.
With over 160 years of cutting and forming thin gauge metal, we have plenty of knowledge to leverage, meaning early involvement means big opportunities to save lifetime cost and improve design and quality for the outset.
For startup companies, this kind of support is especially important. Moving from an idea to mass production is a big step, and one that can be daunting without a partner by your side. Brandauer will hold your hand every step of the way. From the initial prototype to tool design, running DFM reviews, completing initial press trials, and finally delivering ongoing production runs. We have walked this journey many times before, and we will continue to help our customers complete this journey from a single prototype to a full-scale manufacturing success story.
Brandauer engineering consultation – grab ring efficiency
A strong example of Brandauer’s engineering consultation and design in action can be seen in our work with one of the UK’s largest plumbing manufacturers. After years of manufacturing at volume, a goal was set to increase the scale of production. Rather than manufacturing a whole new tool, through DFM methods and working closely with our design and NPI team, we took a different approach.
Adopting an early-stage Design For Manufacture approach, we initially digitally optimised the part to function as efficiently as possible within the tool. Once this was completed, we moved on to the prototype tool. Trialling various methods and designs to achieve the best possible results. Once the prototype had been validated, we built the production tool entirely in-house, giving us full oversight of quality and performance.
The outcomes were game-changing. Output increased from 390ppm to 1,500ppm (parts per minute). That’s over a 3.5x increase in output efficiency over the previous design of the part. For the customer, it meant much faster throughput, lower unit cost and stronger market positioning.
For Brandauer, it allowed us to produce more components not only at a lower cost, but without taking up any more factory space. But most importantly, it meant demonstrating our ability to act as a trusted partner, delivering high-quality, practical improvements to committed Brandauer customers.
All completed, in-house, by Brandauer.
Conclusion
This new chapter in Brandauer’s story isn’t simply about providing faster prototypes or lower-volume production runs; it’s about empowering innovation by introducing precision laser cutting and metal forming. Coupling it with Brandauer’s already proven track record in production, design engineering and consultancy, we can now offer a truly complete service.
From the very conception of the next big idea, right the way through to producing millions of parts per month, Brandauer has done it all, and we are here to assist you at every stage of your project’s journey.
Brandauer isn’t just a components manufacturer; we are a lifetime precision engineering partner.
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