Project Overview
The Southern branch required a bespoke, spring-mounted impact plate for a loading bay environment where repeated vehicle contact was causing significant and costly damage. Vans and lorries striking the bay walls had led to frequent failures of the customer’s existing brackets, resulting in thousands of pounds spent on ongoing repairs. The goal was to create a robust, long-term solution capable of absorbing repeated impacts while remaining durable and suitable for repeat production. With a further 12 loading bays planned, the project also had the potential to develop into a substantial ongoing requirement.
Scope of Work
The project began at concept stage, when Ciaran from the Southern branch approached us with an early “spring sandwich” idea. This initial concept used multiple springs positioned between a metal plate and a rubber mounting system. A physical sample was available, and the correct springs were already being sourced, but the design required engineering input to ensure it could be manufactured reliably and perform effectively in service. We worked closely with Ciaran from the outset, reviewing the concept and sample and providing guidance on how the aluminium plate should be machined to accommodate the spring layout. Through collaborative design discussions, the concept was refined into a structurally sound and repeatable solution. Once the initial trial proved successful, we produced a full technical drawing to formalise the design and support future production.
With the design finalised, we moved into full manufacturer, producing a larger batch of components to meet the customer’s requirements. The aluminium plates were machined to size, pocketed, and tapped M24 to suit six springs – four at the corners and two centrally – along with fixing holes for wall installation. Each unit was supplied with M24 bolts and washers, while the rubber docking plates and springs were provided by the branch. A complementary nylon component was also produced by our team as part of the overall assembly.
Key Highlights
This project is a strong example of how an initial idea can be developed into a fully engineered, production-ready solution. Starting from a rough concept and sample, we supported the design process through trial refinement and documentation, resulting in a component that is both robust and repeatable. the close collaboration between our team and the Southern branch was central to the project’s success, ensuring the final design met both performance requirements and practical installation needs. Most importantly, the finished impact plate significantly reduces damage caused by vehicle impact, addressing a long-standing issue and delivering immediate cost savings for the customer.
Why Choose Bespoke Components
This project highlights the value of bespoke manufacturing when off-the-shelf solutions fail to meet real world-demands. Our ability to support a project from initial concept through to finished production allowed the customer to move away from repeated repairs and towards a durable, engineered solution. By combining machining expertise, design input, and a problem-solving approach, we delivered a product that not only performs reliably but also offers long-term cost savings. The success of this solution has already saved the customer thousands in repairs and has created a platform for future expansion across additional loading bays.
