Development and Engineering
Magnetic Engineering & Custom Solutions: We develop and manufacture your magnetic systems
Precision from concept to series production
Anyone can offer standard solutions – we love a challenge and develop magnetic systems, bespoke solutions or assemblies that are perfectly suited to your application. As innovators and manufacturers, we develop bespoke magnetic solutions where standard products reach their limits.
Behind every successful magnetic system lies a well-thought-out engineering process. At Brugger, we combine decades of experience in magnetic technology with state-of-the-art manufacturing technologies. We support you every step of the way, from the initial sketch through simulation to reliable series production.
On our Special Systems page, you can get an impression of our development services.
For us, engineering means turning your idea into a technically validated solution ready for series production.
At our site in Hardt, we guide you through the entire development process:
-
Design: We plan your optimal magnetic system (CAD & design).
-
Solving: We develop the most efficient production method
-
Validation: We use precise measurements to guarantee that your solution will perform as required.
Certified quality assurance and testing procedures
Reliable automation: High-precision manufacturing through robotics
For our customers, robotics means, above all, consistent quality and competitive prices.
To bring your bespoke magnetic systems into series production, we rely on state-of-the-art machinery featuring integrated robotics and automation. As innovators, we not only develop the product, but often design the appropriate automated production cell at the same time.
-
Fully automated assembly: Our robots carry out high-precision assembly and joining processes that would be virtually impossible to achieve manually with such consistency.
-
Intelligent sensor technology: Integrated camera systems and sensors monitor every step in real time. This enables us to guarantee a 100 per cent first-pass yield directly on the production line.
-
Scalability: Thanks to our automation expertise at our Hardt site, we can deliver projects ranging from small pre-series runs right through to fully automated production on a scale of millions.
For you, this means: maximum process stability and competitiveness – developed and implemented by experts who know how to use automation efficiently for complex magnet assemblies.
Precision laser marking: Permanent marking to meet the highest standards
Laser marking of BRUGGER magnetic systems
A high-quality magnetic system deserves marking that is just as durable as the product itself. With our state-of-the-art laser technology , we offer you precise and indestructible marking directly during the manufacturing process.
-
Counterfeit protection & traceability: We permanently apply serial numbers, batch codes or DataMatrix codes to a wide variety of surfaces.
-
Customised branding: Whether company logos or specific component designations – our laser ensures razor-sharp lettering that withstands even extreme mechanical or chemical stresses.
-
Non-contact finishing: Thanks to the laser-based process, marking is carried out without subjecting the magnetic system to thermal or mechanical stress, thereby fully preserving the material properties.
This integrated process step ensures that your components remain identifiable throughout their entire product life cycle – a crucial component of our comprehensive quality assurance at our Hardt site.
Innovative prototyping: Faster time-to-market through 3D printing
3D printers for prototypes and jigs
Time is a key competitive factor. To shorten development cycles, we rely on additive manufacturing processes (3D printing).
-
Prototyping: Rapid visualisation and functional testing of your components.
-
Fixture and fixture construction: Customised tools for efficient production.
-
Flexibility: Rapid adjustments before the start of large-scale production.
3D printing plays a crucial role in development at BRUGGER. It is used to produce bespoke, complex and high-performance samples and prototypes. It is also used to produce tooling and manufacturing aids. Advances in 3D printing technology enable us to manufacture products with impressive precision and flexibility.
Further advantages of 3D printing:
- Products can be quickly and efficiently adapted and improved throughout the entire development cycle
- Low material consumption during sample production
Validation on the test bench: Certified measurement methods for maximum safety
Trust is good, but measurement data is better. In our in-house test laboratory, our developers and quality assurance staff subject your magnetic systems to the most rigorous stress tests to guarantee that they meet the specified performance criteria under real-world conditions.
Salt spray test for accelerated corrosion testing
A taste of the sea for our magnetic systems
Corrosion resistance is a crucial quality and safety feature for many of our products. In our in-house salt spray chamber, we test the effects of salt spray on the rubber coatings and surfaces of our magnet systems. The salt spray test (in accordance with DIN EN ISO 9227 (NSS test)) is a standardised test for assessing the corrosion protection provided by organic coatings, metallic coatings and chemical or physical surface treatments.
The test is carried out in accordance with various standards. The test specimens are placed under standardised conditions in a test chamber, where a sprayed salt solution acts upon them. The specialised test chamber and the standardised conditions ensure accurate and reliable measurement results for our quality control procedures.
The salt spray test is carried out and monitored continuously until the specified test duration is reached. At BRUGGER, the test duration is usually 1,000 hours. At the end of the test period, any signs of corrosion observed on the test specimens are assessed, for example in terms of the degree of rusting, the extent of blistering and the corrosive under-cutting of organic coatings.
Magnetic measurement technology: Precise validation of magnetic characteristics and load-bearing capacity
Fluxmeter measurement:
Using state-of-the-art fluxmeters and Helmholtz coils, we measure the magnetic flux and the magnetic moment. This ensures consistent magnetic quality throughout the entire series production run.
Adhesion force measurement:
Using precise test set-ups and measuring equipment, we determine the exact detachment or tear-off forces of your magnetic assemblies. In this way, we ensure that the mechanical holding performance precisely meets your requirements.
Specialised measurement technology for client projects: We build measuring instruments when ‘standard’ solutions are not enough
Bespoke measurement technology for maximum precision – development and manufacture of customised measuring instruments
When standard measurement technology reaches its limits, we are your partner for innovative solutions. We develop and manufacture specialised measuring instruments and measurement technology for demanding customer projects – from concept to final implementation. Our range of services covers the entire spectrum of measurement technology, tailored to your individual requirements.
For example, we have designed complex magnetic systems for client projects and subsequently developed complete measurement systems to validate their performance, functionality and precision. Benefit from our many years of experience in precision measurement technology and our expertise in the development of bespoke magnetic technology.
We guarantee measurement accuracy, reliability and seamless integration into your processes.
Drehmoment-Messgerät
Um sicherzustellen, dass unsere Magnetkupplungen den geforderten Spezifikationen entsprechen, hat unser Entwicklungsteam ein speziell auf diese Anwendung angepasstes Drehmoment-Messgerät gebaut.
To validate customer-specific requirements and to precisely characterise our new developments, our engineering team has developed a specialised performance test rig for magnetic couplings.
The system operates on the principle of targeted load application, with the forces generated being recorded by a high-precision Alluris FMI-B20 digital force transducer. Thanks to the sensor’s high sampling rate, we can detect even the slightest changes in force and, using the peak-hold function, precisely determine the maximum breakaway force. The transmissible torque is calculated from this.
A key feature of the system is its integrated linear adjustment: the air gap between the magnetic rotors can be continuously varied via a precision spindle. This enables us to comprehensively document performance curves for various installation scenarios and to tailor our couplings perfectly to the respective application.
Project-specific Helmholtz coil
Bespoke magnetic measurement technology for the most demanding requirements
A Halbach array is a special arrangement of magnets that generates particularly strong magnetic fields – ideal for applications such as electric motors and MRI systems. For a recent client project, we have constructed such an array and developed a project-specific Helmholtz coil to precisely test the raw magnets used in the assembly. The Helmholtz coil generates a homogeneous magnetic field within a comparatively large measurement chamber and is therefore ideally suited to determining the polarisation (anisotropy) of magnets. The test specimens are positioned at the centre of the coil via a double gimbal suspension. When a defined current is applied, the magnets align themselves along their preferred direction (anisotropy axis). This allows for precise verification of whether the actual magnetisation axis corresponds to that specified in the drawing.
As our existing measuring coils were not suitable for this project, we promptly developed a bespoke Helmholtz coil – using AI-assisted calculations, our 3D printer and precision-manufactured windings. The result: a test rig tailored precisely to the requirements of this project.