CAPABILITIES
Conceptualisation & Design
Design Engineered for Real Production
Digital design, simulation and engineering that eliminate rework and accelerate time to market.
Conceptualisation & Design
Design Collaboration That Drives Performance
BCW’s collaborative design model aligns engineering, quality and manufacturing from day one to ensure every component is optimised for functionality, cost efficiency and ease of production.
By validating design intent before tooling or machining begins, issues are resolved early, reducing change cycles and preventing costly downstream revisions. This integrated process delivers refined, production-ready solutions with full digital traceability, enabling faster approvals, improved programme stability and continuous improvement across the entire lifecycle.
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How We Do It
Validated Engineering From Concept to Production
BCW acts as a strategic design partner across NPI, prototype tooling and design-for-manufacture refinement.
Using CATIA V5, advanced FEA simulation and digitally linked FMEA, we evaluate structural performance, tolerance behaviour and manufacturability long before production begins. This early validation ensures robust, compliant and right-first-time outcomes for complex engineering programmes.
We support customers through:
- Digital validation and rapid prototyping
- Material and process selection guidance
- Tolerancing and manufacturability studies
- FEA simulation and FMEA reporting for audit traceability
Design Capability & Technical Environment
BCW’s design capability is based within our Burnley headquarters, forming the front end of more than 300,000 sq. ft. of vertically integrated manufacturing space across Burnley and Wellingborough. Our secure digital environment links directly to machining, fabrication and quality teams, enabling fast feedback, efficient approvals and full traceability from concept to production.
Design Infrastructure and Technical Systems:
- Secure CAD suites
- FEA, CFD and tolerance simulation
- Rapid prototyping
- Digital link to manufacture
- EN1090 design capability
Customer Benefits
Our customers benefit from:
- Early engineering involvement ensures right-first-time manufacture
- Rapid prototyping and digital validation accelerate time to market
- Integrated collaboration between design, quality and production
- Optimised balance of weight, stiffness, strength and cost
- Reduced rework and stronger programme efficiency
VerSATILE engineering services
Industries We Support
BCW’s precision manufacturing expertise supports OEMs and Tier 1 suppliers across:
Aerospace
Automotive
Defence
Off Highway
Power Generation
Rail
Advanced Engineering Solutions
Facility
Our Precision Components Manufacturing operations span BCW’s Burnley and Wellingborough facilities, with over 300,000 sq. ft. of production space dedicated to CNC machining, automation, and precision inspection.
Each site operates under a unified quality system, ensuring repeatable standards across all programmes.
Key facility highlights include:
- Over 90 CNC machining centres, including multi-axis vertical and horizontal platforms
- Automated machining cells for high-volume continuous production
- Dedicated sliding head cell for small, complex parts
- Large component machining area with high-torque horizontal spindles
- Advanced metrology suite featuring CMM, FARO, laser trackers, and surface finish testing
“We have worked with BCW for over a decade, and their commitment to quality, precision, and reliability has consistently exceeded our expectations.
The defence sector demands nothing less than excellence, and BCW has proven to be a trusted partner by delivering high-quality parts on time, every time. Their engineering expertise and unwavering focus on standards give us the confidence that our systems are built on trust and durability.”
John Loughrie
Director of Innovation BAE Systems
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Meet our specialist team
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Let’s Engineer Success Together
Whether you’re developing new technology, scaling production, or strengthening your supply chain, BCW’s vertically integrated approach delivers precision, performance, and partnership at every stage.
Speak to one of our specialists