Among the potential technology solutions presented to us as the ESA Technology Broker UK is a suite of metal component manufacturing processes covering rapid prototyping, low‑volume production and scalable manufacturing via tooling and stamping.
With core services provided by Brandauer including laser cutting, CNC metal forming, wire‑electrical discharge machining (WEDM) and conventional machining, there is also capacity for press‑tool design and precision stamping for higher-volume demands.
The services on offer include prototyping based upon 2D / CAD data and CNC controlled laser cutting. Once cut, the blanks can be formed or bent to a desired shape with CNC-controlled metal forming equipment. Machining and WEDM extends the manufacturing capability to complex geometries, precision features and fine tolerances not easily achievable using forming or cutting alone. This process uses a thin, electrically charged wire and repeated electrical discharges across a dielectric fluid to erode metal in a controlled way, allowing the production of intricate shapes, internal cutouts or thin wall features even in hard or pre-hardened metals. Larger and longer-run requirements can be met through in-house tooling design and press-tool manufacturing.
The services on offer supports the full lifecycle from early-stage and functional prototyping through design iterations and manufacturability testing, to low- or mid-volume production or full production runs, all within the same integrated facility.
Applications include the creation of high-precision, complex shapes where off-the-shelf components are unsuitable. These assemblies provide solutions for aerospace and satellite subsystems, instrumentation, sensor housings, microsystems, power or electronic enclosures, mechanical brackets or interfaces, precision metal sub-components in larger electro-mechanical assemblies, or other high-reliability fields.
Bringing together prototyping, tooling and manufacturing, Brandauer’s working model keeps all phases within one engineering-led structure, ensuring continuity, accountability and traceability, while having open engagement with customers to reduce the risk of late-stage changes, lower total development time, and enable informed decisions about cost, materials, tolerances and production strategy.
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