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Micro-machining Tailor-made EDM automation drives precision at BKV Braun

From Ralf Haßengier 7 min Reading Time

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High automation, deep process integration and in-house fixture expertise enable BKV Braun to manufacture complex precision parts with remarkable efficiency. The subcontractor shows how streamlined workflows and scalable EDM automation can create clear advantages in demanding applications such as medical technology.

Automatic electrode feeding: Together with Sodick and Erowa, the Robot Compact 80 (ERC80) was integrated — including connection to the Zeiss measuring machine and chip-based job management.(Source: d)
Automatic electrode feeding: Together with Sodick and Erowa, the Robot Compact 80 (ERC80) was integrated — including connection to the Zeiss measuring machine and chip-based job management.
(Source: d)

Despite its manageable size, BKV Braun is one of the most innovative subcontractors in the fields of wire erosion, sink erosion, and 5-axis milling. The high degree of automation with only eight employees is just as impressive as the technical level. With machines from Sodick, the company produces highly precise individual parts and small series — primarily for medical technology and special machine construction.

BKV Braun from Meßkirch specializes in high-precision micro-machining — from the production of the finest clamping tools to surgical instruments for spinal surgeries. “We are a classic contract manufacturer in the extended workbench — but with exceptionally high automated manufacturing depth,” says Alexander Braun, Managing Director and Owner of BKV Braun.

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Four specialists in manufacturing oversee a fully automated machinery park: seven wire EDM machines, three sinker EDM machines, a start hole EDM machine, and several automated milling centers — all integrated into a sophisticated manufacturing and job management system. The CAM programming is closely interconnected with production control — an approach that minimizes setup times and incorporates feedback from quality assurance directly into the process.

For clients in the clamping and medical technology sectors, BKV Braun regularly manufactures components in series with tolerances under 0.01 mm. “But that's not our only unique selling point,” emphasizes Managing Director Alexander Braun. “Our advantage lies in the variety of clamping solutions that we develop in-house. Combined parts, which are first milled and then eroded, are standard for us."

Producing fixtures and gripper fingers additively in-house significantly contributes to ensuring quality, process stability, and flexibility. “We manufacture clamping tools for our automation cells ourselves, as well as fixtures for surgical components,” adds Jonas Schlegel, Head of Manufacturing and Quality Management Officer. There are approximately 150 individually adapted clamping tools available — a practical reservoir that proves particularly valuable for complex medical technology components.

It’s hard to believe: four people in manufacturing — and almost everything runs automatically. This is mainly made possible by the seamless integration of Sodick systems into our automation concept.

Alexander Braun, Managing Director and Owner, BKV Braun

Consistent automation implemented

The foray into automation began at BKV Braun as early as 2017 — with a self-built robotic integration on a wire EDM machine. The real boost came during the Covid-19 period when staff was scarce but orders still had to be delivered. Today, most of the manufacturing runs unmanned at night and over the weekend. “During the day, we handle the tedious tasks, at night the machines run and earn money,” says Managing Director Alexander Braun.

Automating the wire EDM area was particularly challenging. When a new Sodick ALC400P was acquired in 2025, it was clear from the start: it would only be implemented with automation. Together with Sodick and EROWA, the Robot Compact 80 (ERC80) was integrated — including the connection to the Zeiss measuring machine and chip-based job management. Automated multi-sided machining with an indexer is also a custom development for BKV Braun. “We didn't want a standard solution, but an individual, scalable automation,” says Alexander Braun.

Sodick was not only a machine supplier but a real development partner: the project was closely accompanied from the early concept phase to interface configuration to CE-compliant commissioning.

Technology with substance

The decisive factor in favor of Sodick was ultimately the combination of technological features, process security, and a well-established partnership. The machine used employs linear drives and absolutely direct measuring systems, has an integrated anti-corrosion system, and is equipped with a Renishaw probe (Renishaw MP250).

Precision was important for BKV Braun not only for the first two years but for many years. “Especially in automated wire EDM for series production, this is a real advantage. Wear-free drives and reliable threading even underwater in the smallest holes are essential for us,” explains Manufacturing Manager Jonas Schlegel. The robust construction ensures stable processes even under demanding conditions.

Additional efficiency gains arise from the seamless integration of CAM automation, measuring technology, and AI-supported programming. In practice, this results in time savings of up to 30 percent — while maintaining high process reliability, even with complex geometries. A decisive aspect, especially for applications in medical technology.

Think modular, act scalable

The automation cell was designed modularly from the outset: a second wire EDM machine can be integrated in the future without much effort. BKV Braun has already had experience with the EROWA Robot Compact 80 from sinker EDM. For several years now, the AG60L sinker EDM machine from Sodick has been operating completely trouble-free and with the highest accuracy with the robotic system.

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“When we invest, it’s to scale,” explains Alexander Braun. And Manufacturing Manager Jonas Schlegel adds: “Machine construction, machine availability, and the well-thought-out system architecture convinced us — not a single failure to this day.”

The system was designed to be open both in software and control. This allows flexible responses to increasing batch sizes or new requirements — without the need for fundamental modifications.

Sustainable automation — efficient and resource-conscious

In addition to technical efficiency, BKV Braun places great importance on resource-conserving operations. A 68 kW photovoltaic system, heat recovery, automatic machine shutdowns, and consistently paperless operations are firmly embedded in the daily business. “Our automation should not only be economically, but also ecologically sensible and must not end with the machine,” emphasizes Alexander Braun.

Sustainability is also considered when choosing materials: where technically possible, the company replaces costly stainless steel with so-called surgical steels like 40-21 — a nickel alloy with good corrosion resistance, high biocompatibility, and excellent machinability. “For many applications — even in mechanical engineering — this is a sensible alternative both economically and technically,” explains the Managing Director.

Currently, around 70 percent of machining tasks involve this material. The high stock availability allows for short response times — an advantage especially for single parts and internal fixture solutions. “We actively advise our customers when it comes to choosing suitable materials,” adds Manufacturing Manager Jonas Schlegel. “Often a successful prototype is enough to initiate a long-term collaboration.”

Communication as a factor for success

A key criterion for success in automation at BKV Braun is cross-team collaboration — especially between manufacturing, CAM programming, IT, and machine and software manufacturers. “Anyone who wants to introduce automation needs to plan more than just acquiring a robot,” specifies Alexander Braun. “It’s about integrating the entire system landscape — from IT to post-processors to measuring technology. Anyone who underestimates this risks stagnation instead of progress.”

This holistic approach at BKV Braun is also thanks to the close cooperation with partners like Sodick, Zeiss, and the CAM provider. Daniel Günzel, Regional Sales Manager at Sodick Germany, highlights: “We consciously decided against an off-the-shelf automation solution. Together with BKV Braun, we developed a solution that is not only tailored to production processes and components but also meets the requirements of users and the expectations of management.”

With this approach, BKV Braun was able to implement an automation concept that goes far beyond mere machine technology — and continues to run reliably, economically, and is continually developed.

“Automation is not a product, but a process”

Short interview with Alexander Braun, Managing Director of BKV Braun

Mr. Braun, you initiated automation at BKV Braun early on — how did that come about?

We started with a self-built robotic integration on our wire EDM machine in 2017 — simply because we knew: if we want to continue working economically, we must make our processes less dependent on human factors. The topic really took off during the Corona pandemic. It became clear how critical staffing shortages can be — but also what can be achieved with sophisticated technology. Today, most of our series production runs unmanned at night and on weekends.

What was your biggest challenge on the way to automated manufacturing?

Clearly: the integration of the entire system landscape. Automation means not buying a robot that then sits pointlessly in a corner. It's about the interfaces between IT, CAM, measuring technology, and machine control. Especially in wire EDM, it requires much coordination and technical understanding. We didn't want a generic solution but something that fits our parts, processes, and people. It was costly, but it was worth it.

What role do in-house developments play in your business concept?

A very large one. We manufacture clamping tools, gripper fingers, and fixtures ourselves — this gives us maximum flexibility and process security. Combined parts that are milled and then eroded are standard for us. And because we develop the clamping technology for this ourselves, we can also automate economically for single parts or smaller batches.

You specifically use surgical steels like 40-21 or 17-4 PH. Why?

On the one hand, because we can replace stainless steel with them — both economically and in terms of processes. 40-21 is biocompatible, corrosion-resistant, and very machinable. This is ideal for many medical technology applications. On the other hand, we stock this material in larger quantities — which shortens our reaction times and makes us independent of fluctuating procurement markets.

What advice would you give other companies looking to enter automation?

Not to think that buying a machine is all there is to it. You have to involve all stakeholders early — manufacturing, IT, software providers — and understand the project as a process, not as a product. It's also important to work with partners who don’t just sell but also think along. Only then does automation truly become a competitive advantage.

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