CASE STUDY: Bespoke Brush Panels for Maximise Engineering Services Ltd

The Challenge

When Maximise Engineering Services Ltd approached Cottam Brush following an online search, they were looking for a cost-effective, UK-manufactured solution for an ageing machine undergoing refurbishment and adaptation.

The machine, an Amada EZ3510, was fitted with brush panels that had become significantly worn over time. However, replacing the existing panels wasn’t quite as straightforward as replicating the originals.

The end customer also wanted to adapt the machine to process 6mm steel sheet, rather than the 3mm material it had originally been designed to accommodate.

This presented two challenges: producing replacement panels that would fit the existing machine accurately, while developing a suitable brush configuration to meet the customer’s new processing requirements.

With the original panels no longer suitable, a bespoke approach was needed.

The Solution

Maximise Engineering Services sent the original brush panels to Cottam’s headquarters in Tyne and Wear, where our Research & Development team began the process of reverse-engineering the existing components.

Rather than simply copying the worn panels, the team developed new technical drawings that retained the precise dimensions and fixing arrangements required for the machine, while incorporating the customer’s updated requirements.

To ensure accuracy, a thorough, multi-stage design and verification process was undertaken:

Initial measurement and design: The first designer carefully measured the original panels and created detailed 3D models and technical drawings.
Independent verification: A second designer remeasured the panels against the drawings, identifying and making any necessary amendments before completing further checks.
Brush configuration assessment: A third designer examined the original tufting arrangements to inform the development of the new brush specification.
Physical testing and approval: MDF templates were produced and checked against the original panels to verify dimensions and fixing positions before the designs were approved for manufacture.

This detailed process ensured that each replacement panel was developed with precision, reducing the risk of fitting issues when installed.

Developing a Bespoke Brush Specification

With the panel designs established, the next challenge was developing a brush configuration suitable for the customer’s new requirements.

Drawing on previous research into tuft patterns, filament arrangements and tuft diameters, Cottam’s R&D team developed a bespoke fill pattern designed around the intended application.

Several configurations were assessed, with test panels produced and trialled on Cottam’s Gemini equipment.

The resulting specification for the majority of the panels was COTTAM Dense – Nylon Trimmed Staggered, a specially developed brush fill arrangement selected for the application.

This ensured that the project went beyond simply replacing worn components, providing a tailored brush solution developed specifically for the refurbished machine.

Manufacturing and Delivery

Following design approval, each brush panel was manufactured at Cottam’s headquarters in Tyne and Wear.

Every panel was individually packed, accompanied by its corresponding technical drawings, brush fill information and reference images to support identification and installation.

Recognising the importance of protecting the finished bristle tufts during transportation, the R&D team also designed and manufactured a bespoke packaging container.

This purpose-built packaging helped protect the brush panels in transit, ensuring they arrived in suitable condition for installation.