UKAEA’s manufacturing services provide advanced, high‑reliability components and assemblies for demanding environments – from fusion and fission to quantum and space. We combine specialist design, precision fabrication and rigorous testing to help organisations turn complex engineering challenges into robust, certifiable solutions.
UKAEA’s manufacturing services are undertaken by specialist teams including the Special Techniques Group (STG), and the Fabrication, Installation and Maintenance Unit.
What we offer
Our facilities and teams cover the full life cycle from concept to qualified hardware.
Machining
- Precision components: High‑accuracy machining for complex geometries
- Demanding materials: Experience with challenging alloys and materials
Additive manufacture
- 3D printing of fusion‑relevant materials: Including CuCrZr and tungsten for high‑heat‑flux and radiation‑tolerant applications
- Design for additive manufacturing: Support to optimise parts for performance, manufacturability and inspection
Joining technologies
- Welding: Specialist welding for critical structures and pressure boundaries
- Brazing: High‑integrity brazing for vacuum, cryogenic and medical systems (such as MRI)
- Diffusion bonding: Robust, leak‑tight joints for complex assemblies and specialist components.
Testing and metrology
- Dimensional metrology: Verification of tight tolerances over long length scales
- Performance testing: Mechanical, thermal and environmental testing to validate designs against real‑world conditions
- Compliance evidence: Data packages to support qualification and certification
Challenges we solve
We focus on the customer’s problem, not just the process. Typical examples include:
- Operating in extreme environments: Components for high temperature, high radiation, vacuum and aggressive media
- Tritium confinement: Design and manufacture of specialist vacuum components and containment systems
- Unusual standards and codes: Joining and fabrication in compliance with RCC‑MR, ISO, ASME and other sector‑specific requirements
- Integration into complex systems: Hardware that must interface reliably with diagnostics, magnets, cryogenics, quantum devices and more
Our manufacturing services
Select one of our services for more information.
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Diffusion bonding
Diffusion bonding involves the joining of parent materials, below their melting point, by heating and applying force in a clean vacuum environment.
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Machining
Our manufacturing team provides a diverse portfolio of machining specialisms for precision components and demanding materials.
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Special Techniques Group
Specialist manufacturing technologies supporting internal UKAEA development, high-tech industry and research institutions globally.
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Vacuum brazing
Vacuum brazing involves the joining of parent materials, below their melting point, by using a molten filler metal in a clean vacuum environment.
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Viewport design and manufacture
We design and manufacture viewports based on our fusion diagnostic windows – proven to operate under harsh conditions with minimal optical distortion.
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Welding
We develop novel welded solutions for fusion challenges, but also supply components to imaging, beam-line, and aerospace customers.
Industries we can support
We can work across multiple sectors and can translate fusion‑driven capability into wider industrial impact.
- Fusion energy research: Components and assemblies for experimental facilities and test rigs
- Aerospace: Specialist welding for spacecraft and satellite hardware subject to severe thermal and mechanical loads
- Medical and MRI: Brazed assemblies and vacuum components for MRI systems
- Oil and gas: Equipment for aggressive, corrosive environments and high pressures
- Quantum and advanced computing: Ultra‑clean, ultra‑stable vacuum and optical components for next‑generation systems
Looking for a manufacturing partner for a complex engineering challenge? Our specialists can support design, fabrication, testing and qualification.
Case studies
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UKAEA viewports support quantum computing at the Technical University of Vienna
UKAEA’s optical viewports supported TU Vienna’s quantum research, enabling single-atom manipulation with clarity, vacuum integrity and reliability.
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Pioneering optical viewports for next-generation quantum systems
UKAEA’s precision optical viewport boosts quantum research with ultra-high performance, vacuum-ready design and cross-industry applications.
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Collaboration across borders: fabrication of testing capsules for NIFT‑E
UKAEA fabricated and assembled 8 NIFT-E test capsules—636 material specimens across 18 types—for INL irradiation testing.
