A six-week tooling programme for a global dispensing systems manufacturer has demonstrated how Brigham Pressings is combining design-for-manufacture expertise, toolmaking and high-volume presswork to help customers improve products destined for demanding assembly environments.
Brigham Pressings has completed a fast-track tooling and manufacturing project for a global supplier of hand-held chemical dispensing systems used across automotive and aerospace assembly lines.
The Birmingham-based precision metal pressings specialist was approached to support the redesign of a chemical-compound applicator, with the customer seeking a lighter and more ergonomic assembly capable of improving change-over performance for operators.
With an annual production requirement of 900,000 units, the programme called for a solution designed from the outset around repeatable, high-volume manufacture.
For Brigham Pressings CEO Doug Allen, the project highlights the value manufacturers can unlock by involving an experienced presswork partner during the product development process.
“The greatest value we can often bring to a customer starts well before the first component comes off the press,” said Allen. “By combining design-for-manufacture thinking with our knowledge of tooling, materials and high-volume presswork, we can help shape a component around both its end use and the way it will ultimately be manufactured.”
Working collaboratively with the customer, Brigham Pressings held a series of design-for-manufacture (DFM) workshops to translate the original CAD concept into two production-ready pressed components.
Manufactured from DC04 mild steel in 2.3mm and 1.6mm thicknesses, the components were developed using 3D modelling to refine the finger contours and improve operator ergonomics while retaining the existing mounting envelope.
That compatibility meant the redesigned assembly could integrate directly into the customer’s existing production environment while delivering the required improvements in handling and servicing.
The programme also placed tooling at the centre of the manufacturing strategy. New wear-resistant dies were developed with maintenance and long-term production requirements incorporated into their design.
Brigham Pressings Managing Director Allan Murray said the project reflects the company’s ability to bring together engineering knowledge and practical manufacturing experience.
“This was a great example of collaborative engineering translating directly into a production solution,” said Murray. “We were working towards very clear objectives around ergonomics, change-over performance, production volume and delivery, so every element of the tooling and presswork strategy was developed with those outcomes in mind.”
Speed was another defining feature of the programme. Brigham Pressings completed the tool build within six weeks, followed by a further week of on-site commissioning to bring both dies up to full production speed.
The resulting tooling was qualified to support production volumes of 900,000 units per year, with manufacture allocated across Brigham Pressings press capability, including Chin Fong, Bruderer and S&B equipment.
On-site trials also validated the ergonomic improvements. Operators confirmed that the redesigned assembly achieved the required hand-force parameters and target change-over time, supporting smoother component changes within high-speed automotive and aerospace production environments.
“A six-week tool build requires close coordination between engineering, tooling, production and the customer,” added Murray. “That joined-up approach is one of Brigham’s strengths. We can take a project from the initial engineering discussion through tool development, trials and commissioning and then into repeat production.”
The programme illustrates a broader evolution in the role of specialist presswork manufacturers within modern supply chains.
For customers developing components for automotive, aerospace and other advanced manufacturing applications, the manufacturing partner can increasingly contribute during product development — helping optimise material choice, component geometry, tooling strategy, production efficiency and scalability.
Brigham Pressings combines precision metal pressings and stampings, presswork, tooling, design-for-manufacture support and project management within a manufacturing operation equipped to support both technically demanding projects and high-volume production.
Its quality and environmental management systems are supported by ISO 9001 and ISO 14001 certification, alongside the company’s wider experience serving demanding engineering sectors.
Allen believes that combination of engineering input and manufacturing capability is becoming increasingly valuable as customers look to move new products efficiently from concept into serial production.
“Customers want manufacturing partners who understand the complete journey,” he said. “Our role is to use our experience in pressings, tooling and production engineering to make that journey as efficient as possible. This project is a strong example: a redesigned product, new tooling delivered in six weeks and a manufacturing solution capable of supporting 900,000 units every year.”
The outcome was equally clear from the customer’s perspective. “The new tooling went in flawlessly and delivery performance has been excellent.”
For Brigham Pressings, the project provides another example of how early engineering collaboration, responsive toolmaking and established high-volume presswork capability can turn a product improvement brief into a production-ready manufacturing solution.