SUBCONTRACTING NEWS

Two new automotive contracts secured by Brandauer

Brandauer has secured two major automotive contracts, reinforcing its strategy to evolve into a long-term engineering partner for global clients. The Birmingham-based manufacturer, which recently completed a management buy-out, is now working with Ford Motor Company and a leading Eastern European tier one supplier on projects focused on electrification.

Both collaborations highlight Brandauer’s shift towards early-stage engagement, offering consultancy and design for manufacturing support before progressing through tooling, production and automation to full-scale volume output. This end-to-end approach aligns with the company’s growth ambitions and its target of reaching £12m in revenue by 2029.

Chief executive Rowan Crozier says the business is transitioning from a traditional stamping specialist into a full-service precision engineering partner capable of supporting customers from concept through to high-volume global supply. He notes that automotive remains a key sector, particularly as electrification drives demand for increasingly advanced and precise components.

A milestone within the Ford project sees Brandauer manufacturing a lamination progression tool exceeding 2500 mm in diameter for the first time. The solution incorporates integrated automation to stamp, bond, stack and skew thin-gauge laminations for electric vehicle applications, demonstrating new approaches to motor production. The company has supported the programme with design validation, prototyping and process expertise, with full tool manufacture now underway.

The second contract follows a similar model, centred on the development of a fully automated production line featuring multiple high-performance tools to maximise efficiency and tolerance control.

Together, these projects underline Brandauer’s expanding capabilities and its commitment to delivering integrated engineering solutions, supported by ongoing investment in skills, technology and quality standards.

More information www.brandauer.co.uk

A new turn in performance for Cogsdill Nuneaton

Cogsdill Nuneaton Ltd has strengthened its turning operations following investment in a
DNX 2100SB multi-tasking mill-turn machine supplied by Mills CNC. Installed in December
2025, the machine is playing a central role in the company’s drive to improve efficiency,
increase capacity and move towards lights-out production.
The DNX 2100SB, one of the first installed in the UK, supports the machining of complex,
high-precision parts in a single set up. Equipped with twin spindles, a B-axis milling head, 60-
tool ATC and FANUC control, the machine also incorporates a Hydrafeed bar feeder, rotary
parts accumulator and Renishaw probing and tool-setting systems to support automated,
unattended operation.
The investment follows an internal audit of Cogsdill Nuneaton’s turning section, which
identified bottlenecks caused by ageing CNC lathes and labour-intensive processes.
According to managing director Lee Donaldson, the decision to invest in a multi-tasking
machine from Mills CNC was influenced by previous positive experience of Doosan machines
supplied by the company, as well as its strong pre- and after-sales support. Training
provided by Mills CNC ensured a smooth transition to the new FANUC-controlled platform,
helping operators and programmers quickly become productive.
Since installation, the DNX 2100SB has been busy machining small batches of precision
components for the company’s standard tooling products in a single hit, achieving tight
tolerances, excellent roundness and high surface finishes.

Ultimately, the investment marks a significant step forward in productivity, flexibility and
overall machining capability. Looking ahead, Cogsdill Nuneaton plans to expand the
machine’s role to include more complex and custom parts, while introducing overnight
unattended running.
More information www.millscnc.co.uk

UK foundry buys estate

A major UK foundry has reinforced its commitment to the Black Country with the purchase of the Moxley Industrial Estate. Alucast, which provides high-pressure, low-pressure, sand and gravity casting services, has spent £1.8m on the site in Wednesbury, protecting the future of it three current units and supporting estate neighbours Kingfisher Enamelling Co and BES Group Testing. Located just a few miles from the M6 and M5 motorways, the 5-acre site is well-known in the local manufacturing community and has been home to Alucast for nearly 65 years.

More information www.alucast.co.uk

€45m casting investment

Horse Powertrain, a global specialist in low-emission propulsion systems, has invested €45m to expand cylinder-head casting processes at its plant in Valladolid, Spain. The new aluminium casting facility will be the first in the country to cast cylinder heads using the tilting gravity die casting (TGDC) process. Compared with traditional high-pressure die casting, TGDC enhances the structural integrity of finished components. Once this investment comes online, Valladolid’s annual production capacity for cylinder heads will rise from 300,000 to 360,000 and yield 150 new roles.

More information www.horse-powertrain.com

Strategic investment underpins growth at ComplexaHPE

Precision injection moulding, machining and tooling specialist ComplexaHPE is reporting a record order book following more than £2m of investment in advanced manufacturing technology and a strategic focus on supplier collaboration, including a close partnership with Erodex UK.

Formed in 2021 through the merger of ComplexaTools and High Precision Engineering (HPE), the business provides a full turnkey service spanning toolmaking, precision machining and injection moulding. The strategy is delivering results, with new contracts secured in the UK, Ireland and overseas, particularly within high-end medical manufacturing.

Group managing director Paul McHugh attributes the growth to sustained investment and integrated capability: “Customers increasingly want a complete solution, from design for manufacture through to final sign-off, including end-of-arm tooling and inspection fixtures. That reduces lead times and ensures consistent quality.

Since 2021, the company has installed high-speed milling machines, five-axis machining centres, spark and wire EDM systems, and a Mazak Millturn, alongside robotics and palletisation to support lights-out production. However, McHugh emphasises that machinery alone is not enough.

“Maximising performance is critical, and that’s where Erodex has added real value,” he says.

Following a review of EDM processes, Erodex recommended POCO EDM graphite grades to optimise electrode performance and consistency. In automated, unattended environments, predictable material behaviour is essential. The result has been improved machinability, longer electrode life, reduced cycle times and enhanced surface finishes.

With nearly 24 months of work secured, ComplexaHPE is experiencing unprecedented demand.

“Our success is built on quality, technical expertise and strong supplier partnerships,” concludes McHugh. “Working closely with Erodex has helped us raise standards and strengthen our competitive position in precision manufacturing.”

More information www.erodex.comTop of Form