Specialised Systems: Bespoke Solutions & Customised Magnetic Systems
Customised systems – When standard solutions aren’t enough.
Do you have a technical challenge for which there is no ‘off-the-shelf’ solution? Standard products often reach their limits when faced with complex challenges. For over 60 years , we at BRUGGER have been developing and manufacturing magnetic systems that do exactly what they’re supposed to do – no more, no less. Over 3,500 completed bespoke projects prove that we understand complex requirements and turn them into reality ready for series production. Your project deserves more than just a standard component!
For specialised systems, we offer two ways to find your bespoke solution:
If you have a specific problem relating to magnet or fastening technology, we don’t just offer you a component – we offer a genuine solution. However, not every problem calls for a revolution. Sometimes a clever evolution is enough.
That’s why we offer a range of approaches, depending on what makes the most sense for your project.
Modification of existing products (modified standard systems): Often, it is sufficient simply to modify a magnet system already featured in our catalogue. The shape and basic design of the standard range are retained. We can make flexible adjustments to height, length, diameter, surface finish, mounting, holding force and material. As these variants can often be manufactured from existing standard components, the major advantage lies in short lead times and cost-effective production – even for small batches.
Examples and further information
Development of bespoke products: Many demanding applications call for a completely new, optimal solution. We are your expert partner in this regard. We have many years’ experience in the processing of magnets, metals and plastics.
Thanks to our high level of in-house production capability and our high-performance machinery, we can develop the perfect system solution for you. With our in-house tool and prototype manufacturing facilities, we provide you with reliable support from the first prototype right through to finished series production.
Examples and further information
Specialised systems for sophisticated drive technology
We have built up in-depth expertise in certain areas of application. If your project falls into one of these categories, you will find technical information and application examples on the relevant pages:
| System | Typical application | Your benefits |
|---|---|---|
| Magnetic couplings | Pumps, agitators, dosing technology | Hermetic separation, wear-free operation |
| Ring-gap systems | Sensors, precision guides | Highest positioning accuracy |
| Magnetic rotors | Motors, generators | Compact design, high power density |
| Magnetic chain drive | Conveyor technology, automation | Low-maintenance continuous operation |
🔗 Magnetic couplings
🔗 Ring-gap systems
🔗 Magnetic rotors
🔗 Magnetic chain drive
“In addition to implementing the project in accordance with the specifications, the project management involved an in-depth technical analysis of the requirements, which enabled additional opportunities for optimisation to be identified at an early stage and integrated into the solution development. Thanks to BRUGGER’s willingness to share its technical expertise with us as customers, it was possible to create a premium product – both technically and economically – from the prototype stage through pre-production to full-scale production.”
Product Manager & Project Manager, Thomas Hirschberger, NEXOPART GmbH & Co.KG
Everything under one roof: the benefits you gain from our vertical integration
Are you looking for a supplier or a technology partner? BRUGGER is both.
We combine consultancy, design, toolmaking and manufacturing under one roof. For you, this means: full control over quality, costs and deadlines.
We manufacture products regardless of material (e.g. metal or plastic housings) or batch size, utilising state-of-the-art machinery. We have our own in-house toolmaking facility, which means short lines of communication between development and production, as well as faster response times – no long waits for external suppliers. Our flexible assembly department carries out complex assemblies using precise bonding, pressing, riveting and assembly techniques.
Our machinery for your ideas:
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CNC turning: For maximum precision in complex rotationally symmetrical parts.
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Electrical discharge machining (EDM): To produce even the finest details and most intricate contours whilst minimising wear on the tools.
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Stamping and pressing tools: For highly efficient and scalable series production.
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State-of-the-art riveting systems: For high-strength, durable material joints.
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3D printing: Innovative prototyping and rapid time-to-market through 3D printing (including metal 3D printing)
Engineering consultancy: We bring your ideas to life
We are experts in the customisation and further development of complete joining technologies – from magnetic clamps and magnetic plugs to innovative magnetic connectors. And even if your final product does not require a magnet at all: we are here to support you with our comprehensive manufacturing expertise.
Ready for your magnetic solution?
Let’s work together to find out how we can meet your requirements:
Stephan Zenner
Sales Consultant - Technical Application Consultant
Jurisdiction: Germany (postcode 6/7/8/9/0), Croatia, Austria, Poland, Switzerland, Serbia, Slovakia, Slovenia, Czech Republic and Hungary
Robert Stuhlberg
Sales Consultant - Technical Application Consultant
Jurisdiction: Germany (postcode 1-5), Benelux, Denmark, France, Greece, Italy, Norway, Portugal, Sweden, Spain and UK
Engineering & Prototyping – our development process
As an experienced manufacturer, we at BRUGGER support the entire engineering process, from the initial idea through to design and right up to series production. A certified quality management system and rigorous testing procedures ensure the reliability and precision of your bespoke magnet solutions when they are put into service.
Find out more about what we can offer here.
1. Requirements analysis
Our sales team and developers work closely with you to understand your specific requirements and objectives. In doing so, we analyse existing challenges and identify specific areas for improvement.
2. Solution Consultation
Based on the needs analysis, our development team advises you on the best technological solutions and customisation options. If no solution is available based on existing products, we work with you to develop new, tailor-made solutions.
3. Prototyping & Testing
We create prototypes and carry out extensive testing to ensure that your new magnetic solutions meet all requirements and function reliably.
4. Ongoing Support & Further Development
If required, we can continue to provide technical support for your product range even after its market launch. We take your feedback on board and continuously optimise the solutions – adapting them to your changing requirements.