Wales-based Wall Colmonoy is poised to revolutionise UK defence manufacturing with the development of one of the country’s most advanced commercially available vacuum casting foundries. Through the Defence Technology Exploitation Programme (DTEP) funded by the Defence and Security Accelerator (DASA), the company has forged a strategic partnership with Rolls-Royce, accelerating the production of next-generation aerospace engine components. This initiative not only strengthens the UK’s defence industrial base but also sets a new standard for accessibility and innovation in the sector.
The foundry, set to become operational in August 2025, will enable the recycling of legacy aerospace parts, transforming valuable first and second-generation alloys into components for modern applications. This capability is crucial for addressing supply chain challenges and enhancing sustainability within the defence sector. The facility will also serve as a resource for the wider defence and industrial manufacturing community, democratising access to advanced casting technology.
Wall Colmonoy’s investment in a state-of-the-art vacuum casting furnace represents a significant leap forward in defence manufacturing. The furnace, capable of producing components up to 200 kilograms, will operate in a high-vacuum, oxygen-free environment, ensuring superior material integrity and performance. This technology, traditionally confined to large corporations, will now be available to a broader range of UK manufacturers, fostering faster and more efficient production of high-quality components.
The company’s ‘digital twin’ approach to casting technology further enhances its innovative capabilities. By creating detailed simulations of metal temperatures, pouring rates, and shell designs, Wall Colmonoy can virtually test castings before physical production. This approach reduces waste, lowers costs, and accelerates development timelines for critical defence components.
Through DTEP, Wall Colmonoy has also established a strategic partnership with Rolls-Royce, dedicating approximately one-third of the foundry’s capacity to Rolls-Royce aerospace applications. This collaboration accelerates the development cycle for component design, reinforcing the UK’s position as a leader in aerospace innovation.
The foundry’s ability to recycle legacy materials aligns with broader defence objectives around resource efficiency and supply chain resilience. By reformulating these high-quality materials into modern alloys, Wall Colmonoy addresses supply chain challenges and delivers significant cost and sustainability benefits.
DASA’s flexible funding approach has been instrumental in the project’s success. When the opportunity arose to purchase a larger system, DASA’s adaptive funding framework allowed Wall Colmonoy to adjust its plans, enhancing long-term capabilities.
As the foundry nears completion, Wall Colmonoy is already looking ahead to future projects. The company’s commitment to innovation and strategic investments ensures it will remain at the forefront of defence manufacturing. With the first castings planned for early September 2025, the foundry is set to become one of the busiest parts of the plant, driving the UK’s defence industrial base forward.
This initiative underscores the importance of public-private partnerships in advancing defence technology. By leveraging DASA’s funding and expertise, Wall Colmonoy is not only strengthening the UK’s defence capabilities but also setting a new benchmark for innovation and accessibility in the sector. As the defence landscape evolves, such collaborations will be crucial in ensuring that the UK remains at the cutting edge of military technology.
