The UK's ambition for a revitalised nuclear sector is clear: a secure, low-carbon energy supply that underpins national prosperity and delivers on net zero commitments.

Katherine Bennett, chief executive officer at the High Value Manufacturing (HVM) Catapult, explores the fundamental pillars of policy, technology and skills required to achieve this ambition; and Charles Carpenter, head of research for the AMRC's nuclear manufacturing group, shares why nuclear must turn to advanced manufacturing technologies to catch up with surging demand.

The nuclear equation: policy, skills and technology 

By Katherine Bennett, chief executive officer at the High Value Manufacturing Catapult

Global demand for affordable, resilient, secure and clean energy is rising – and nuclear is part of the answer. As the UK stands on the cusp of a nuclear renaissance, the crucial question isn't just if we can build new plants, but how we industrialise their manufacture at scale and pace. 

I believe success hinges on three areas: coherent policy, cutting-edge technology and a highly skilled workforce. Without alignment and sustained investment across these critical areas, the promise of a secure, low-carbon energy future for the UK will remain out of reach.

At the High Value Manufacturing (HVM) Catapult, a network spanning 23 sites, employing 3,500 people and having driven over a billion pounds of investment since 2011, we are uniquely positioned to accelerate industrial transformation by helping academia, industry and government tackle manufacturing's toughest challenges across these very pillars.

Policy is the first pillar, providing essential market certainty. 

According to the recent Clean Energy Industries Sector Plan, there are huge opportunities for the UK, especially as an exporter in the global civil nuclear market, projected to be worth one-trillion pounds by 2030. Government decisions backing Sizewell C and selecting Rolls-Royce SMR as the preferred bidder demonstrate a real vote of confidence in UK manufacturing – signalling to investors, supply chains and future engineers that the UK is committed to clean energy. 

However, fully seizing these opportunities will require investment, scale, rate and certainty to boost capacity; and the existing capacity deficit necessitates direct, coordinated action from industry, regulators, government and academia – with HVM Catapult as a core delivery partner.

To meet the unprecedented demand, we must rethink how nuclear components are made. This brings us to the second pillar of technology. 

We are working with industry and regulators to turn engineering challenges into opportunities. Our programmes actively support the government's nuclear ambitions by mobilising UK manufacturers for the global market, accelerating new nuclear builds and providing crucial innovation support for Small Modular Reactors (SMRs) – critical for data centres and sustainable aviation fuel. 

We’re unlocking opportunities with partners like Sellafield in decommissioning and increasing domestic testing and validation capacity to ensure components are manufactured and assured in the UK before being sold worldwide. 

This is built on a strong foundation of collaboration between our six centres and the nuclear industry, with the AMRC delivering a strong pipeline of projects for Sellafield, UK Atomic Energy Authority, Cavendish and Rolls-Royce among others. 

Earlier this year, the AMRC created a new nuclear manufacturing group following the integration of staff from the former Nuclear AMRC. This move retained talented engineers and researchers, and over £35 million of production equipment within the network. These changes aim to safeguard the UK’s renowned nuclear expertise, strengthen HVM Catapult’s support for the sector and ultimately increase its scale, competitiveness and future investment.

But cutting-edge technology and robust policy mean little without the skilled individuals to bring them to life. This is where the third pillar - skills - becomes paramount. 

Our centres are foresighting future needs and training the next generation, as demonstrated by the AMRC Training Centre’s nuclear degree apprenticeship. Beyond new talent, they’re upskilling current workforce and helping staff transition from declining industries to emerging ones. We must rise to these challenges at the same time as the demand across defence, aerospace and offshore wind increases rapidly.

For the UK to extract maximum economic value and create thousands of well-paid, secure jobs, we must invest and modernise now. No single organisation can do it alone. This once-in-a-generation opportunity demands a strategic, multi-partner approach – and HVM Catapult stands ready to play its full part in solidifying the policy, skills and technology bedrock for our nuclear future.

Industrialising innovation: The AMRC's blueprint for nuclear manufacturing

By Charles Carpenter, head of research for AMRC’s nuclear manufacturing group

Over 12 years ago, I moved to the UK, arriving amidst the buzz of a nuclear renaissance. The world was eager to build new nuclear plants, but that momentum, sadly, faded. Now, a decade later, it's back – and stronger than ever.

Today, the conversation has fundamentally shifted. It's no longer just 'what are we building?', but 'why now?'. This global commitment, fuelled by the energy crisis, net zero targets and the imperative for clean, affordable, secure and resilient energy, suggests the current momentum is here to stay. We're witnessing nations commit to tripling nuclear energy, financial institutions seeing nuclear as an investable sector, and tech giants like Google and Microsoft partnering to deploy nuclear solutions.

With the world watching, now is our time to deliver.

But this sheer demand raises a vital question: Can we actually manufacture all required components at scale? Think beyond the reactor pressure vessel, consider the kilometres of piping, thousands of pumps and valves that would be needed to construct every new reactor.

Delivering on time and within budget isn't just about efficiency; it requires a crucial shift towards digital technologies and 'fast-follower' approaches – quickly applying lessons learned from other sectors. This is precisely what we're doing at the AMRC.

Our work demonstrates how advanced manufacturing technologies are making the UK's nuclear ambitions a reality. We stand at the forefront, supporting the sector with innovative manufacturing and material methods such as electron beam welding (EBW), powder metallurgy hot isostatic pressing (PM HIP), additive manufacturing, cold spray and diode laser cladding (DLC). 

For example, EBW, an autogenous method requiring no welding wire, significantly reduces material usage, heat input, distortion, energy consumption and carbon dioxide emissions. Another technology PM HIP is for large, high-integrity components. This method addresses the challenge of expanding the supply chain beyond traditional forging and casting, which often face long lead times and limited availability – offering a vital alternative manufacturing route for critical components. 

Our project with the US Department of Energy and Electric Power Research Institute to reduce nuclear pressure vessel manufacturing time for SMRs is a powerful example of advanced technology in nuclear. 

The results are transformational. Utilising techniques like electron beam welding and diode laser cladding, we cut production time by 50 per cent, cost by 40 per cent and slashed the lead time from 2.5 years to under 12 months. 

For the lower assembly of the vessel, using just two EBW welds, we reduced welding time from 538 hours to 5.4 hours. Energy usage plummeted from 3,200 to 170 megajoules, a 174 kg CO2e reduction, and material usage was cut by 584 kilograms. 

For the two-meter diameter upper assembly demonstrator, we anticipate further reductions in machining time, energy and emissions, material usage, welds and inspection, and expect to share results in 2026. This vessel serves as a vital demonstrator, de-risking the adoption of these processes for other critical plant items like pipes and valves.

How do these innovations fit within industry standards and regulatory frameworks?

Integrating these advanced methods into established codes and standards is a significant part of our work. The AMRC engages with international bodies like American Society of Mechanical Engineers who are strategically incorporating advanced manufacturing. 

Equally the role of regulators is crucial in ensuring safe technology adoption. The AMRC regularly engages with UK regulators, including the globally recognised Office for Nuclear Regulation which leads international collaborations to streamline regulations for advanced manufacturing and materials. Such collaboration between research, industry and regulators is vital for truly accelerating the delivery of the UK's nuclear future.

My message to UK manufacturing, particularly those navigating declining industries or grappling with rising material costs, is clear: demand is coming rapidly. 

Whether from nuclear, hydrogen or other energy sectors, the need for components is immense. And those ready to embrace advanced manufacturing technologies will discover incredible opportunities.

To become preferred domestic suppliers, we must invest in digital methods and advanced manufacturing now. This commitment will allow us to build the critical components that power Britain's clean energy future.