[member="WD-334"],
Alright sounds good! For droid model, I think most of us in canon are either HK droids or some sort of war droids captured by droids from Mechanus raiding various convoys during star wars, but I think it might be cool if he was actually a droid made by the Sith, like one of the Old Republic models or maybe a newer one from Chaos canon, it could be a nice conflict since during his stay with Metal Lords there would have been that stigma against the Sith associated with him, it's within our code to not make any deals with the Sith.
Name was the two most common schemes I noticed was just using their serial number/designation, like HK-36 or WD-334, for him it might be something like SD-827 or SWD-182, or using titles they took up once becoming a Metal Lord and use them as their new name to distance themselves from their past of serving organics, like the Iron Lord, Lord Mettallum, Lord Abomination. He could use something like The Crimson Lord or the Lord of Rust or the Betrayed King, since being banished he wouldn't have to worry about keeping other machines as his equals.
How strong their force should be, I would say maybe some cruisers, and then frigates and corvettes to back them up plus drone or droid forces to crew them and board others. It would be enough to be a threat to us so we would have to send multiple Metal Lords on the job, but it's not too much, equivalent to what a Minor Faction could field basically.
As to why they were banished, probably because they broke the Metal Lord code, it could have been by making deals with the Sith and people found out, or because they decided to try and take over a planet or ships by just mass murdering some innocent traders or farmers. It could have been also because they were really vocal about how droids and organics should not work together so when HK rose to power he basically framed the droid and got him banished by the Sparklords to get him out of the way so he would not screw up his plan for Metal Lords diplomacy wise.