Isembard team members (l-r) Justin Baucum, U.S. Expansion Lead; Brandon Nguyen, CNC Engineer; Alexander Liu, Engineer; Rory Rose, Manufacturing Engineer; Jacob Rustad, CNC Programmer; Zoe Hatton, Manufacturing Engineer; Jack Williams, Machining Engineer; Maximilian Eichler, Chief of Staff; Josh Miller, General Manager
Isembard, a UK-founded startup expanding rapidly in the United States, has announced the opening of a new Dallas-Fort Worth, TX, area factory, expanding production capacity to support customers across defense, aerospace, and energy.
The new facility builds on Isembard's growing U.S. footprint as manufacturers across critical sectors work to diversify supply chains, reduce lead times, and strengthen domestic production capability.
"Opening this facility is an important milestone for Isembard and the customers we support," said Justin Baucum, U.S. Expansion Lead, Isembard. "Dallas-Fort Worth is one of the most strategically positioned manufacturing regions in the country. With expanded capacity here, we can move faster, produce more, and help reduce lead times without compromising on quality."
Spanning 25,000 sq. ft., the new factory marks Isembard's second facility in the Dallas-Fort Worth area and will serve as the company's U.S. headquarters for its rapidly growing team. The site is outfitted with precision CNC mills, lathes, and additional equipment, enabling exponential capacity growth with the objective of producing high-quality parts for critical industries where speed, reliability, and precision are essential.
In the new facility's first year, Isembard is taking a phased approach to ensure it can provide scalable capacity to meet growing customer demand:
- Phase 1-DN Cell (initial high-rigidity 5-axis and turning foundation): This includes a DN Solutions DVF 5000 with pallet changer; a DN Solutions SVM 4100 high-speed VMC; DN Solutions DNM 5700 with 4-axis rotary; and DN Solutions Puma DNT 2600 high-performance CNC lathe.
- Phase 2-Okuma Cell (advanced multitasking and ultra-precision expansion, focusing on mill-turn and high-dynamic 5-axis for reduced setups and titanium/Inconel work): This features an Okuma Multus U3000 or U4000 mill-turn center; Okuma MU-5000V or MU-6300V high-accuracy 5-axis VMCs; Okuma LB3000 or LB4000 series lathe with milling for hybrid turning/milling); and Okuma MB-5000H or similar horizontal for larger production runs with pallet system integration.
- Phase 3-Premium multitasking and automation cell (high-end scaling with top-tier mill-turn and 5-axis systems): It will include a Mazak Integrex i-series (Integrex i-800 or j-200) DONE-IN-ONE mill-turn; DMG MORI NTX 2500 or NTX 3000 hybrid mill-turn; Hermle C 42 U or C 52 U MT 5-axis machining center, optionally with mill-turn table; and additional automation, including robot tending cell + CMM/probing upgrades.
The Dallas-Fort Worth factory will run on Isembard's proprietary software operating system, MasonOS, which helps manage and optimize manufacturing workflows from quoting and scheduling through production and quality control. The system helps standardize operations and improve speed and consistency across every Isembard facility, drawing on the company's operating experience across both the U.S. and the U.K.
"We opened our first U.S. Isembard factory in July 2025 with a single CNC machine," Baucum added. "Now, as we look to the next chapter, we are on track to increase our manufacturing capacity by 20x within the four walls of this new facility. Small starts forge great arsenals, and this expansion is only the beginning."
Isembard will support demand in Texas and nationwide while working closely with domestic material suppliers and regional partners to strengthen U.S. manufacturing resilience.
For more information contact:
Isembard
1221 Champion Circle, Unit 103
Carrollton, TX 75006
contact@isembard.com
www.isembard.com