Future-Proofing Aluminium Radiant Panel Production
At the end of 2025, BAL Group reached a critical turning point. Historically, we relied on external suppliers for large quantities of fully formed copper meanders—the thermal core of our highly efficient aluminium radiant panels. However, as global supply chain disruptions increased throughout the year, the risk of missing critical delivery deadlines became a reality.
For a business built on a reputation for short lead times and next-day delivery, this external dependency was a risk we could no longer take. Our decision to invest in a bespoke CNC bending machine wasn’t just about buying hardware; it was a strategic move to bring production in-house and gain total control over our quality and schedule.
Our recently commissioned CNC machine brings precision tube manipulation directly onto our factory floor. It is built to handle a versatile range of materials and diameters which ensures we can easily adapt to the changing needs of the HVAC and thermal management sectors.
Multi-Material Capability: Copper, Aluminium and Stainless Steel
The machine processes three core materials:
Copper: The primary choice for our meanders due to its superior thermal conductivity.
Aluminium: Used for lightweight structural thermal components.
Stainless Steel: For specialist applications requiring high corrosion resistance.
Precision Diameter Range (6mm to 15mm)
While the machine easily handles a broad diameter range from 6mm to 15mm, its main focus is on the 12mm and 15mm tube requirements used in our flagship radiant ranges.
Strategic Partnership with Lawton Tubes
A vital part of this transition was developing our raw material sourcing. In order to move away from buying pre-formed components, we needed a reliable partner who could supply high-quality raw material in a format ready for automated bending.
Transitioning From Pre-Formed Meanders to Level Wound Coils
We initially approached several suppliers, ultimately choosing to partner with Lawton Tubes based in Coventry, the UK’s leading copper tube manufacturer. Their technical team provided invaluable advice on the correct specifications for copper in coil—specifically Level Wound Coils (LWC).
Technical Benefits of LWC for CNC Bending
Using LWC allows for continuous production runs with minimal downtime. The copper is fed directly into the CNC machine, straightened, and bent to exact meander patterns. This automated process removes the weak points that can be caused when tubes are bent by hand.
Compliance with BS EN 14037 Standards
By performing the bending process in-house, we guarantee that every panel meets the rigorous BS EN 14037 standards. This ensures that the thermal output is consistent across the entire surface of the panel, providing our clients in the health and education sectors with verified performance data.
Aluminium Radiant Panels: Optimising Plus & Pro Lines
The main driver behind our new CNC tube bending machine is to make our core heating panels work even better. By forming the copper pipes inside our UK factory, we can fit them tightly against the front aluminium panel to ensure maximum contact between the two metals. Eliminating these gaps means heat travels much faster, warming spaces far more efficiently.
Spectrum Pro: High-Performance 15mm Integration
Our Spectrum Pro range integrates 15mm tube meanders within a durable 2mm aluminium extrusion. This combination delivers excellent thermal mass and fast response times, making it ideal for demanding commercial heating applications.
Spectrum Plus: Versatility in 12mm Tube Design
For projects requiring a lighter profile, the Spectrum Plus range uses 12mm meanders. Thanks to the precision of our new CNC machine, we can achieve tighter bend radii. This means we can pack more “thermal length” into each panel, increasing the total BTU output per square metre.
Emerging Markets: Custom Copper Heat Pipes
While setting up the new machinery, our engineering team spotted an exciting new market opportunity. Many of our long-standing Aluminium Heatsink customers have frequently been asking us for integrated cooling solutions.
Solving Thermal Management Challenges in Electronics
As modern electronic components become smaller and more powerful, traditional air cooling is often not adequate. We are now using our CNC bending technology to create custom-formed copper heat pipes that provide a solution for this issue.
Benefits of Custom Copper Heat Pipes for Electronics Cooling
Excellent Thermal Conductivity: Copper naturally transfers heat rapidly (~400 W/m·K) to protect sensitive electronics from overheating.
Complex 3D Geometry: The CNC machine can form pipes into complex layouts, allowing them to fit perfectly inside tight server racks or compact automotive battery packs.
Lightweight Efficiency: Pairing these copper pipes with our custom Aluminium Extrusions gives customers a hybrid solution that maximizes cooling without adding unnecessary weight.
Conclusion: A New Era for BAL Group Manufacturing
The successful commissioning of our CNC bending machine marks a turning point for BAL Group’s supply chain independence. We are no longer at the mercy of external factors such as shipping delays for our core components.
Steve Kane, Managing Director of BAL Group, explains: “While other suppliers are struggling with unpredictable global supply chains, we have brought 100% of our copper forming in-house. When you order our Radiant Plus or Pro panels, you aren’t just buying a product – you are buying peace of mind and a guaranteed timeline.”
About BAL Group
BAL Group is a leading UK manufacturer of aluminium extrusions, radiant panels and heatsinks, dedicated to providing high-quality thermal solutions world-wide.
by david@dm-design.co.uk
