Fastening Points

At bigHead, technical support is a partnership. Whether it’s a new composite panel for an electric vehicle, cladding for a building, or even a helicopter under development, customers rely on our bespoke process to find a fastening solution that fits.

At the centre of this process is Oli, one of the first people you’ll speak to if your challenge can’t be solved with a standard fastener.

We caught up with Oli to find out what his typical day looks like as a development engineer – and how his work helps transform ideas into confident outcomes.

New fastening challenges: putting together the puzzle

Oli talks fastening solutions at bigHead’s Verwood site

“My job is a bit like putting together a puzzle,” Oli explains. “Distributors and direct customers come to us when they’re not quite sure what they need. Maybe they can’t find the right fastener on our website, or maybe they’re dealing with a new material or assembly method. My first role is to understand what they’re trying to do.”

From the moment he logs on at his satellite office near Cranfield University, Oli is jumping between industries, applications and technical detail. No two days are the same.

“One minute I’m talking to someone about fastening in a wind turbine moulding, and the next I’m sketching out fastener installation options for a new camper van interior. It’s very collaborative.”

“We’ll get on a Teams call, share screens, and ask them to walk us through their component and their full manufacturing process – what they’re making, what it needs to do, and how a bigHead fastener might integrate.”

Looking at fastening holistically

As the conversation unfolds, Oli works with the customer to distil their needs into a clear set of fastening requirements. That could mean exploring how the fastener will be used (such as surface bonding vs embedding), and practical installation methods. Or specific fastening requirements, like corrosion resistance or load performance.

The bespoke process follows five stages: define, design, develop, decide and deliver. Oli’s goal is always the same: to make sure the fastening solution works first time in the customer’s world.

“It’s a lot of zooming in and out,” he says. “I’m thinking about fine mechanical detail one minute and then stepping back to look at the overall picture across design, manufacture and assembly.”

Oli and his colleagues still find time to get hands-on in the lab. “We’ll make test panels, bond fasteners, run a mini programme and prepare a report with the results. It’s really satisfying when you can give someone clear, tested evidence that the solution will work.”

Helicopters, boats and beyond

Oli works on fastener production at the Verwood site

The sheer variety of projects is exciting. “Two weeks ago I visited a helicopter startup,” Oli says. “They were in the early stages of development and wanted to know, can bigHeads work in this application? So they invited me to come down to their factory and walk them through it.”

It’s a regular part of the job. “We’ve worked on everything from EV interiors to reinforced concrete cladding. I’m heading to a boat show tomorrow to see one of our customer’s products in the final application. That’s a really rewarding part of what I do.”

Hardest part of the job?

Oli admits a challenge of his role is balancing time across such a diverse workload. “Because bigHeads are so versatile, we get pulled in a lot of directions. I give every customer the time and depth their challenge deserves, and that takes energy.”

But there’s another frustration, too: when customers come to bigHead too late.

“We’ve had cases where we can see the right answer, but the design’s too far along. It would take too much rework. That’s tough, because we really want to help – but sometimes we can’t without a compromise. That’s why we always encourage teams to involve us early, even if it’s just an exploratory chat.”

From karting to composite engineering

Oli at Cranfield Tech Park

Oli’s path into engineering began with motorsport. “I was into Formula 1 and go-karting as a teenager, which led me to study automotive engineering at university. During my degree I started working with composites, especially thermoplastics, and got really interested in how they can be recycled and processed.”

That curiosity took him to Cranfield University for a master’s, where his thesis explored how metallic inserts could be integrated into composite materials. At the Cranfield composites centre, he met bigHead, who were sponsoring a project there.

“When I finished my degree, they offered me a chance to complete some follow-on work, and then a full-time role.”

That was three years ago. Now, as well as collaborating fortnightly at bigHead’s Verwood site, Oli stays connected to the academic environment at Cranfield. He even sponsors student projects: “I’ve come full circle!”

Any career advice for those looking to get into fastening?

Here’s Oli’s advice: “Don’t be afraid of being confronted with a problem and not knowing the answer! Fastening – and engineering as a whole – is so complex, and it’s impossible to know all the answers at first. The key is to take the time to ask the questions and conduct the necessary research and investigations.”

So, what’s the best part of the job?

For Oli, it’s those early conversations. “When someone comes to us with complex requirements and concerns, and I can help translate that into a real, workable solution.”

He also loves the learning involved in working with such a diverse range of applications. “Every enquiry gives me the chance to learn or improve on something, which is so rewarding!”

Oli’s approach is calm, curious and practical. He doesn’t just solve problems. He prevents them, by embedding fastening considerations into the earliest stages of design.

Next time you start a new project…

If you’re not sure whether a fastener exists for your design challenge, or if you’re planning to do something new with composites, there’s every chance Oli might be the one to help.

Whether on screen, in the lab, or on site, he’s one of the people who makes sure that your fastening solution works first time across design, manufacture and assembly.

Contact Oli