News Archive

At BCW Design & Manufacture, our commitment to engineering excellence drives continual investment in tools and talent. Our latest advancement enhanced Finite Element Analysis (FEA) capability is already addressing real-world challenges for our aerospace clients by enabling predictive validation of complex structures ahead of manufacture. 

Why FEA is a Critical Engineering Tool    Finite Element Analysis (FEA) enables engineers to simulate the physical behaviour of parts and assemblies under operational conditions well before any material is cut or components are...

As an engineering leader planning the next automotive manufacturing component or programme, you're focused on delivering performance, efficiency, and reliability. Your team's expertise is ready, and the project holds significant potential. But a crucial manufacturing question often arises early in development: Which production process – Computer Numerical Control (CNC) machining or high-pressure die casting – is the optimal choice for this specific component? 

Understanding when to specify a machined component or when to opt for die casting, or when a combined approach is best, is a decision that significantly shapes component cost, quality, production speed, and ultimately, programme success within the demanding automotive landscape.

The automotive manufacturing sector is undergoing a significant transition, driven by trends from electrification to demands for greater supply chain resilience. Within this evolving landscape, aluminium extrusions in automotive design and production are a key enabling technology. Their adoption carries considerable implications for vehicle performance, sustainability metrics, engineering design approaches, procurement strategies, and overall manufacturing efficiency.

While adopting any new material strategy requires diligent evaluation of integration requirements and potential risks, the performance advantages of aluminium extrusions are well-established. As the industry pushes further into lightweighting, Electric Vehicle (EV) platform development, and enhanced structural performance, understanding how to leverage aluminium effectively becomes essential for forward-thinking automotive manufacturing engineering teams seeking competitive advantages.

This blog examines the increasing role of aluminium extrusions in critical automotive components, addressing the complex engineering challenges they solve and outlining practical considerations for implementation. From robust crash management systems designed to absorb and dissipate energy effectively, to sophisticated BIW structures and EV battery enclosures requiring high levels of protection and thermal management, extrusions play a vital role in modern automotive engineering. They offer the precision, consistency, and favourable strength-to-weight ratios needed to meet stringent performance standards while supporting critical emissions reduction and sustainability targets.

But as engineering and procurement teams push for lighter, greener, and more efficient components, the challenge remains: how do you balance performance, sustainability, and cost without adding complexity?

For Lauren, becoming a mum hasn’t changed her career ambitions it’s strengthened them. Already highly driven, Lauren has found that motherhood has given her even more purpose, confidence and resilience. The challenges she’s overcome as a parent have equipped her with a fresh perspective on work and leadership, helping her to lead with greater empathy and flexibility. 

In this Q&A, Lauren shares how she balances her role at BCW with family life, what she enjoys most about working in engineering, and the skills that have helped her thrive both at home and in the workplace. 

The pace of change in automotive engineering has accelerated, and 2025 is shaping up to be a defining year. As platforms evolve and production pressures mount, engineering teams face new challenges in material selection, supply chain, and delivery expectations.

These five automotive manufacturing trends are already reshaping how components are designed, sourced, and manufactured - redefining what engineers expect from their suppliers.

At BCW Design & Manufacture, we’re proud to have built a team of talented and dedicated individuals, over the last few days, we’ve been introducing the talented individuals behind our success. Rounding off our sales team is Steve Rosella our Proposal Manager.