Case Studies


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Client: AES Cirrus
Project: Produce panels and components for the medical industry

AES Cirrus component manufacture AES Cirrus panel manufacture

Overview:

AES Cirrus originally came to Bray after becoming dissatisfied with their previous supplier. They were looking for Bray to be able to reproduce some of their current product range.

Challenges:

To produce various glove ports, doors, panels and component to tolerance and specified standard.

Solutions:

Bray used their extensive experience and knowledge of machining and fabricating difficult materials such as Premac® and other components for the medical industry to produce quality items in an effective and efficient way, suggesting where any improvement in design or production could be made.

Outcome:

Bray successfully reproduced the components for AES and now work with them on many new projects and designs too.
 
AES Cirrus glove port manufacture AES Cirrus glove port manufacture

 

Testimonial:

We have worked with Bray Plastics on many projects over the last few years. Their knowledge base and experience mean they continuously provide quality products and a high level of customer service. We have found them be professional, reliable and their insights and input have been extremely beneficial in the design, manufacture and fabrication of our components. The team at Bray are friendly, capable and flexible and a pleasure to do business with.

AES Cirrus

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Client: Mechline Developments
Project: Development and Production of a Commercial Kitchen Dispenser Housing

Mechline plastic product manufacture Mechline plastic dispenser Mechline plastic dispenser manufacture

Overview:

Mechline Developments, who supply the commercial kitchen/restaurant industry, had identified a new product opportunity. Having designed and produced a first prototype, they needed to engineer a production version.

Challenges:

Cost, functionality and external appearance were all of critical importance.

Solutions:
Prototype mould Solidworks IGES files were used and turned into machine code using Mastercam. Resin was then machined on our CNC router to produce the prototype vacuum mould.
Skin A skin was then taken from the prototype mould once the prototype vacuum forming had been approved. This skin was used to produce the production mould.
Production Mould   Having proved the prototype mould the production mould was manufactured using high temperature resin from the skin.
Production Components were stacked ready for assembly.
Assembly We sourced and fitted hinges, locks, inserts etc and assembled the unit.
Packing After assembly we inspected and packed the unit for dispatch.

 

Outcome:

Bray produced a product which exceeded expectations and led to a very successful launch and roll out.

Testimonial:

BRAY are an extremely professional company, we’ve always been pleased with the quality of service and the quality of the end products. BRAY are responsive to our issues & fulfil every order with speed, efficiency, professionalism & commitment. BRAY continue to do excellent job & we always feel we have achieved value for the money. The team are responsive, accurate and an absolute pleasure to work with. I would highly recommend them, and I look forward to continuing to work with them in the future.
Ged Mowatt
Mechline Developments

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Client: EKA
Project: NATO Recovery Vehicle

Nato plastic product manufacture EKA plastic product manufacture EKV machining of aluminium

Overview:

Bray was asked for alternative options to reduce costs on an existing component.

Challenges:

Identifying the technical requirements and perimeters. Then proof testing.

Solutions:

Bray sourced a suitable alternative material with substantial cost savings.

Outcome:

Having tested the component an order for over 2400 units was received.

Testimonial:

Can I take this opportunity to thank you and your staff for all the cooperation (and understanding!) we at EKA have received in the development and supply of components for our current Ministry of Defence project.

It is always a pleasure to deal with companies, whose expertise in fields where we are lacking knowledge and experience meets our expectations.

Having visited you personally with my ‘Quality Managers’ hat on, it is clear that EKA can use your services both in development and production at little to no risk and it is always a pleasure to see systems in place for the control of your diversity of products.

We hope that our recent experience with you as a new supplier to EKA develops into a long and mutually beneficial relationship to both of us.

Ian Kelly
Director and Quality Manager

EKA Limited

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Client: Inzpire Ltd
Project: Military Pilot Tablet Knee Mount

Knee mount manufacture
image-1170

Overview:

Inzpire Limited required an effective solution to a problem associated with supporting a Tablet PC on a pilot’s knee under the extremely demanding conditions of military aircraft operation. It would be used in both fast jet and rotary wing applications.

Having already tried a major manufacturer for a solution which was unsuccessful, Inzpire then came to Bray for help with an extremely tight deadline.

Challenges:

To develop a low cost functional solution able to comply with in theatre operations and aerospace standards.

Solutions:

Bray consulted intensively with the customer and aircrew to ensure design perimeters were met.

Outcome:

Inzpire kneemount for tabletCustomised enclosure for kneemounted tabletCustomised enclosure for kneemounted tablet. Military equipment manufacture - plastic forming and enclosures.

Bray produced a first production unit within 6 weeks of initial instructions with over 300 units supplied on the first order. Bray continues to work closely with Inzpire on future projects.

The final Knee-Mount solution has transformed the way the Inzpire GECO system is used by its military customers.

Testimonial:

Right from the start, Bray Plastics impressed us with their efficient, professional manner – an approach that not only inspired confidence, but also generated the results we were looking for. By partnering with Bray Plastics, we have been able to consistently meet our customers’ demanding delivery timeline. Geoff’s team has been extremely energetic, self-motivated and able to swiftly build and assimilate our design ideas and information. We were also impressed with their Project management skills, communication abilities and capability to convey and sell their recommendations to the Inzpire team. Thanks for the excellent service and we look forward to working with Bray Plastics for the foreseeable future.

Mark Boyes
Mission Systems Director
Inzpire Limited

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Client: Aston Martin
Project: Reverse engineering

Aston Martin reverse engineering

Overview:

Many customers have product or components no longer available for a variety of reasons.  Bray can take these components and duplicate them either on a one off basis or volume production.

Bray Plastics were asked to reverse engineer an existing production forming by a prestige car manufacturer.

Challenges:

To reproduce production tooling from the original mould accounting for material shrinkage.

Solutions:

Bray reproduced section tooling which was reassembled taking shrinkage into account.

Outcome:

Orders were placed by Aston Martin for a specific custom application.

New tooling was manufactured from the original mouldings taking into account distortion and shrinkage.

The final forms were produced from fire retardant ABS.

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Client: World Leader in Polishing Optics
Project: To replace a stainless steel collection tray with a vacuum formed slurry collection tray

Manufacture of plastic equipment for medical industry

 

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Client: Metrology equipment manufacturer
Project: Microfocal X-ray cabinet

Vacuum formed panels for xray medical equipment

Overview:

Improve the aesthetics of the steel cabinet with vacuum formed panels.

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Client: World leaders in refrigerated packing
Project: To produce prototype components machined in styrene and vacuum formings to short timescales.

Styrene prototype components machined in styrene and vacuum formings to short timescales

 

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Our Services

 

3D Printing and scanning
Prototyping and Tooling
Vacuum Forming
Machining
Fabrication
Enclosures
Assembly
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Want to know more?

Explore our featured case studies to see how our end-to-end services can benefit your business

Bray Plastics Ltd
Cherrycourt Way
Leighton Buzzard
Bedfordshire
LU7 4UH
United Kingdom

Phone: 01525 219100
bray@brayplastics.co.uk

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