Design From Concept To Production

How a request for a better awning bracket turned into a fully engineered stainless steel range, proven on our in-house test rig and verified by independent FEA.

We occasionally made awning brackets for a few companies using 60x40x3mm mild steel box section, but we were never keen on producing them. They inevitably rusted and corroded, often leaving unsightly rust stains over time. The manufacturing process also left exposed holes that needed plastic bungs, which looked unattractive on the side of a house supporting an otherwise well finished awning. When we were asked whether we could manufacture a stainless steel awning bracket, we got to work.

With our in-house CAD team we designed the first stainless steel spreader bracket, and then went on to design gutter brackets, sign brackets, pipe brackets and a bespoke service for everything in between.

The first stainless steel spreader bracket, designed in-house.

From a single spreader to a full family of bracket designs.

The gutter bracket, engineered to clear a building’s guttering cleanly.

Proving Strength On Our Test Rig

We were very happy with the final versions of these products, but wanted to prove they are stronger than the mild steel versions. So we built a test rig capable of applying up to 3 tonnes of pressure. We tested the mild steel brackets first and they collapsed at 250 kg. Complete structural failure.

We then put our stainless steel brackets through the same rig. We reached 450 kg on the gutter brackets and 250 kg on the standard spreaders, and we have never reached a point of failure. Only deflection.

A bracket fixtured into our in-house rig, ready for load.

Applying calibrated load by hand against a load cell.

Independent FEA For A Quality Guarantee

Load cells recorded the results, and we were astounded at the strength we had engineered into our products. But that wasn’t enough on its own. To back up the physical results and offer our customers a proper quality guarantee, we commissioned independent computer analysis, and once again the numbers were fantastic.

Independent FEA showing von Mises stress distribution under design load.

Total displacement plot, deflection scale 10, well within design limits.

Better Looking, Longer Lasting, Stronger

The independent results matched our in-house physical tests, and together they let us offer our customers a better looking product that outperforms others on strength and lasts longer without corrosion. We know we make the best awning brackets, not just as our opinion, but because we have rigorously tested them ourselves and had them verified independently.

The finished assembly, designed, tested and built in Birmingham, UK.