Manufacturing Case Studies –
Metal Fabrication & Precision Machining

Universal Fabrications worked with a spin-out company from Oxford University to prototype a precision machined aluminium enclosure for a DNA sequencing machine. The device is used to identify variants in the genetic makeup of humans, animals and plants. With over 45 years’ experience in precision machining and complex metal fabrication, we were able to support a high-tech client at the critical prototype stage.

Universal Fabrications worked with NP Aerospace on the XC Off-Road Suspension System upgrade for the British Army’s Mastiff and Ridgback heavy armoured vehicles. Alongside programme partners HORIBA-MIRA, Horstman, Texelis and Tyron, we manufactured complex sheet metal fabrications for the new suspension system. With over 45 years’ experience manufacturing complex metal fabrications for security, policing and defence, we were well placed to deliver to the programme’s demanding timescales.

Ree Automotive, an industry-leading commercial vehicle provider, contracted Universal Fabrications to manufacture a self-driving 3.5-tonne electric vehicle chassis for its product launch in Las Vegas. Working from a design developed with Williams Advanced Engineering, we provided full project management through to delivery. With over 45 years’ experience manufacturing complex metal fabrications for the automotive, specialist vehicle and defence sectors, we were able to take the chassis from drawings to finished, painted units on a fixed launch date.

BMW’s Hams Hall plant in Birmingham expanded its storage facility to house over 6,700 combustion engines, moved by an automated conveyor system. Universal Fabrications was contracted to manufacture and install the engine stillages (platens) that carry each engine through the system. With over 45 years’ experience manufacturing complex metal fabrications for the automotive, specialist vehicle and defence sectors, we combined robotic welding and precision machining to deliver at production scale.

The West Midlands Combined Authority (WMCA) launched a regional cycle hire scheme, delivered in conjunction with Serco and Pashley Cycles. Universal Fabrications manufactured the docking stations and associated street furniture, now installed at major transport hubs and city centres across the region. With over 45 years’ experience manufacturing complex metal fabrications for infrastructure, transport and defence, we were well placed to deliver durable, public-facing products at scale.

Universal Fabrications worked with Babcock to design and manufacture a number of police vehicle security cage variants, for both specialist and fleet vehicles. With over 45 years’ experience manufacturing complex metal fabrications for security, policing and defence, we approached each cage as an integrated part of the vehicle. This included packaging considerations, strength, usability and installation together rather than supplying an off-the-shelf product.

Universal Fabrications manufactured a battery box for external defence use, designed by our customer and prepared for manufacture by our in-house design team. With over 45 years’ experience manufacturing complex metal fabrications for security, policing and defence, we were able to turn the customer’s design into a part that was quick to sign off, strong where it counted and cost-efficient to produce.

Universal Fabrications was asked to engineer a design solution to hold the service pipes on the tunnel boring machine (TBM) for the Channel Tunnel Rail Link. With over 45 years’ experience manufacturing complex metal fabrications for rail, tunnelling and defence, we combined design and manufacture to help win the contract for our customer.

Universal Fabrications developed an automotive lifting solution built around a gas strut to assist with lifting the load. The result is an easy-to-carry, easy-to-use system made from sheet metal components and TIG welded together. With over 45 years’ experience manufacturing complex metal fabrications for the automotive, specialist vehicle and defence sectors, we understand how to balance strength, weight and usability.

Universal Fabrications was asked to machine a two-piece differential casing from solid aluminium, working from the customer’s 3D model. With tight time constraints and very tight tolerances, this was a job tailor-made for one of our lead engineers. With over 45 years’ experience in precision machining and complex fabrication for the automotive, specialist vehicle and defence sectors, we delivered on both quality and time.

Universal Fabrications manufactured a hot swap electronics housing as part of a large order of over 100 parts and assemblies, with multiple finish options. With over 45 years’ experience manufacturing complex sheet metal fabrications and enclosures, we provided the production management needed to deliver the whole order in a way that made our client’s assembly simple.

Universal Fabrications worked with a defence customer to develop a new shaft support housing. Through close collaboration between our design engineers and the customer, the project moved away from costly machined items to a more cost-effective laser cut fabrication that was quicker to produce. With over 45 years’ experience manufacturing complex metal fabrications for security, policing and defence, we know where fabrication can deliver the same performance for less.

Universal Fabrications was asked to produce a customer’s air flow diagnostic housing from three separately drawn parts. Our engineers responded with a redesigned one-piece solution that removed the weld assembly altogether. With over 45 years’ experience manufacturing welded fabrications, machined fabrications and stand-alone precision machined parts, we don’t just make what’s drawn, we look for opportunities to improve it.