As a global pioneer in Fibre Reinforced Polymer (FRP) infrastructure, Australian manufacturer Wagners Composite Fibre Technologies (CFT) combines cutting-edge manufacturing with a highly skilled engineering team whose creativity, technical precision, and field experience fuel continuous innovation.
The team designs and builds purpose-built machinery in-house, ensuring exceptional quality, enhanced efficiency and continuous improvement throughout every phase of Wagner CFT’s manufacturing process.
Joining as the new Engineering Manager, David Brander is set to lead the team in pushing the boundaries of innovation and shaping the future of manufacturing excellence.
“Our engineering team is a diverse mix of mechanical engineers, project engineers, R&D specialists, and technical support staff,” David Brander said.
“We’ve got people who thrive on design and innovation, others who are hands-on problem solvers on the workshop floor, and a few who bridge the gap between product development and production,” Mr Brander said.
“Together, they bring the right blend of creativity, technical know-how, and practical experience to turn ideas into real, working machinery,” he said.
“We design and build custom equipment that supports our pultrusion and composite manufacturing lines.”
“Everything from resin handling systems to the automated cutting, finishing, and testing stations.”
“The aim is to create machinery that perfectly fits our processes rather than forcing our processes to fit someone else’s equipment.”
Pictured – Production Engineer, James Bourke at the first filament winding trial at UniSQ.
What started as a practical solution to a manufacturing challenge has grown into a cornerstone of Wagners CFT’s innovation.
“Wagners has been designing its own machinery for decades. It really started out of necessity when commercial systems didn’t exist for what we wanted to do with composites,” David Brander said.
“Over time, it’s evolved from one-off solutions to a more structured in-house capability, where engineering and R&D now work hand-in-hand to continuously refine and innovate,” Mr Brander said.
“It is important for us to design and build our own machinery because our work is highly specialised,” he said.
“Designing our own machinery ensures we can innovate faster and adapt to the unique needs of composite manufacturing.”
“It also means we’re not limited by what’s available on the market, we can build exactly what we need to achieve the best outcomes.”
“Because we design in-house, every piece of equipment is engineered around our specific materials, production rates, and product requirements.”
“Off-the-shelf systems rarely account for the unique challenges of FRP manufacturing, so our designs tend to be more efficient, more adaptable, and better integrated into our workflows.”
Pictured – Earth Friendly Concrete (EFC) R&D Manager, Russell Genrich, Technical Lead, Dr Ali Mohammed and Global Utilities Lead, James Lorrimer during a utility pole demonstration.
Purpose-designed machinery forms the foundation for maintaining control, consistency and innovation throughout the FRP manufacturing process.
“Our machines are the backbone of how we maintain quality and efficiency,” David Brander said.
“The right machinery allows us to control every stage of the process, from fibre placement and resin flow to curing and finishing,” Mr Brander said.
“This ensures our products meet the high standards expected in infrastructure and construction applications,” he said.
“Designing our machinery in-house gives us agility. When new products or challenges come up, we can design, prototype, and implement changes quickly without waiting on external suppliers.”
“It also means we protect our internal protocol and maintain a deep understanding of the technology driving our production.”
Pictured – R&D Engineer, David Bolin and Pultrusion Operations Manager, Joseph Wac wrapping the mandrel at the fifth filament winding trial.
Creating machinery is a team effort that brings together expertise from across the business.
“The design and development of our machinery is a genuinely collaborative effort,” David Brander said.
“The core design work sits with our Production Engineering and R&D teams, but we regularly draw input from operations, maintenance, and our workshop crew,” Mr Brander said.
“Everyone involved has a shared goal of building equipment that’s safe, efficient, and purpose-built for composite manufacturing,” he said.
“We’re closely connected with production, QA, and the commercial teams, as well as our colleagues in R&D.”
“There’s constant back-and-forth between engineering and production to make sure our designs translate well into everyday use.”
“We also work with customers and partners from time to time when tailoring project-specific designs and product-specific tooling or systems.”
Pictured – Engineering and R&D staff during the filament winding trials.
From concept to construction, each machine is carefully developed to meet specific production needs.
“The Engineering team is pretty much involved from the beginning and the need for new machinery usually starts with a challenge or an idea,” David Brander said.
“As soon as a new idea or product concept comes up, we’re part of the conversation, scoping feasibility, assessing manufacturing impacts, and planning what equipment or process changes might be needed,” Mr Brander said.
“The design and development of our machinery all happens at our Wellcamp manufacturing facility just outside of Toowoomba,” he said.
“We move through concept sketches, 3D modelling, and simulations, then build and test prototypes before full-scale fabrication.”
“Throughout the process, the team works closely with production to make sure the end product is practical, safe, and effective.”
“The close proximity to our production lines means we can test, iterate, and improve designs in real time.”
“There’s a strong sense of ownership because the people designing the machinery also get to see it in action.”
Pictured – Production Engineer, Bilal Abduljabbar and Engineering Manager, David Brander working on the injection moulding machine.
Innovation is driven by ideas and insights from every part of the business.
“Ideas for new machinery come from everywhere. Some come from R&D when developing new products, others from production staff who see opportunities for improvement on the floor,” David Brander said.
“We also capture feedback from maintenance, safety, and quality teams, it’s a continuous loop of ideas and refinement,” Mr Brander said.
“We have a really open feedback loop. Operators and supervisors are encouraged to share observations or improvement ideas, and those often spark the next round of design tweaks or upgrades. It’s very much a team-driven process,” he said.
“Innovation drives efficiency, consistency, and product performance.”
“FRP technology is always evolving, and staying ahead means constantly looking for smarter ways to manufacture.”
“Whether that’s through automation, better process control, or improved safety and sustainability.”
Pictured – R&D Engineer, David Bolin preparing the filament winding mandrel.
Unlike traditional materials, composites require a delicate balance of control and precision.
“Composites behave differently from traditional materials like steel or concrete,” David Brander said.
“Tailored machines allow us to control things like layup, tension, temperature, and resin flow with precision,” Mr Brander said.
“That level of control is essential for achieving the strength and quality our products are known for,” he said.
“By designing machines that are purpose-built, we eliminate a lot of variability in the process.”
“Automation and data feedback help us fine-tune production and reduce waste, which improves both quality and throughput.”
Pictured – Wagners CFT Engineering and R&D teams at the testing facilities at UniSQ.
David Brander brings a wealth of engineering and leadership experience and a commitment to collaboration, innovation and continuous improvement to his role as Engineering Manager.
“I’ve spent my career in engineering and manufacturing, working across R&D, project delivery and leadership roles,” David Brander said.
“I’ve always enjoyed working in environments where design, innovation, and practical problem-solving come together, which is what drew me to this space,” Mr Brander said.
“Wagners has a strong reputation for innovation in composites, and I saw a real chance to build on that by strengthening our internal engineering capability,” he said.
“My first few months have been great. There’s a lot of energy and expertise in the team, and I’ve really enjoyed getting to know the people behind the machinery.”
“Seeing ideas turn into working solutions, and the pride the team takes in that has been a highlight.”
“My vision for the Engineering team is to keep building a culture that values collaboration, continuous improvement, and curiosity.”
“I want us to be known not just for the machines we design, but for how well we work together to solve complex problems.”
Pictured – Engineering Manager, David Brander assessing the filament winding mandrel in the R&D lab.
With exciting projects and innovations underway, the door is open for engineers and problem-solvers eager to contribute and grow.
“There’s a lot of exciting development work currently happening behind the scenes including the commencement of our new line of filament wound profiles and several additional pull-winding machines to increase business capacity and meet current supply demand for utility poles,” David Brander said.
“2026 will be a big year full of capital projects bringing not only more production capacity but also new technology, new ideas, smarter systems, and a real drive to keep improving how we do things,” Mr Brander said.
“As our work continues to expand, we’re always interested in connecting with bright, motivated engineers who share our drive for innovation.”
“If you’re ready to take the next step in your career and contribute to meaningful projects within a collaborative, forward-thinking team, we’d love to hear from you.”
Connect with Engineering Manager, David Brander via email (david.brander@wagner.com.au) or the Contact Us form if you’re interested in learning more about our engineering innovations or exploring career opportunities within the Wagners CFT team – https://www.wagnerscft.com.au/contact-us/
Read ‘How is FRP made?’ to discover the fascinating manufacturing process behind our advanced composite materials – https://www.wagnerscft.com.au/resources/our-frp-manufacturing-process/
For more information, watch ‘Introduction to Wagners CFT and how we produce one of the world’s strongest pultruded FRP products’ – https://www.youtube.com/watch?v=hhS2KF41EAE&t=1061s
