The UK has established its first sovereign manufacturing
capability for ultrahigh temperature materials - vital for space,
hypersonic and propulsion systems.
Cross Manufacturing Ltd, a third-generation family business, has
built the UK's first pilot-scale end-to-end manufacturing process
for Ceramic Matrix Composites (CMCs). And the Defence Science
and Technology Laboratory (Dstl) has
invested in this important development.
More about CMCs
CMCs are
lightweight yet as strong as metal. They are capable of
withstanding temperatures exceeding 1,000°C—hotter than molten
lava.
Unlike conventional metals, they hold their strength and shape
under extreme heat and stress. These properties make them
essential for:
- Space – protecting spacecraft and satellite components during
launch and atmospheric re‑entry
- hypersonics – enabling vehicles to travel at more than 5
times the speed of sound while enduring intense aerodynamic
heating
- advanced propulsion – where components must survive prolonged
exposure to extreme temperatures
Bringing an important technology back into the
UK
Cross Manufacturing Ltd employ around 550 people operating
facilities in Bath and in Wiltshire. The company co-invested in
the capability's development, seeing it as a major growth
opportunity across both civilian and defence
aerospace.
The UK has historically relied heavily on overseas suppliers for
these specialist materials, but this work brings a critical
technology onshore, strengthening supply chain resilience and
ensuring the UK can independently design and manufacture
strategic materials.
Dstl Chief
Executive Dr Paul Hollinshead said:
This achievement demonstrates how defence investment in science
and technology drives high value jobs, advanced manufacturing and
regional economic growth.
By moving rapidly from laboratory research to an industrially
relevant pilot production line, the programme has accelerated the
UK's ability to convert scientific excellence into deployable
capability.
Collaborating with industry and academia
Funded by the MOD's Chief Scientific Adviser, Cross Manufacturing
Ltd worked in partnership with Dstl, the
University of Oxford, the National Composites Centre and UK
Atomic Energy Authority as well as defence industry firms QinetiQ
and MBDA.
The collaboration has delivered a dedicated pilot facility
capable of producing consistent, high‑quality composite materials
at a scale ready for transition to full industrial production.
Dstl Materials
Engineer Chris Hawkins said:
This milestone represents a significant enhancement of UK
sovereign capability. These advanced materials will underpin
future defence systems, space technologies and high‑temperature
applications. Just as importantly, this investment strengthens UK
manufacturing, supports skilled jobs and helps ensure we retain
control over critical technologies.
Dr Talha J. Pirzada, Research & Technology Manager at Cross
Manufacturing Ltd, said:
Through this programme we have successfully transformed UK
expertise from research into pilot‑scale manufacturing. The
consortium now holds the capability to produce demonstrator
components from oxide‑based ceramic matrix composites—a first for
the UK. This sets the foundation for a fully sovereign production
capability.
Producing and testing demonstrator components
During development, the team produced and tested demonstrator
components which included:
- nose cones
- curved panels
- high temperature seals
Mechanical testing was conducted at temperatures of 1,000°C.
As the nation marks British Science Week, this achievement is
both scientific and strategic; reducing reliance on overseas
supply chains and strengthening the UK's freedom to operate in
space and hypersonics – in step with the ambitions of the
Defence Industrial
Strategy.
