Nuclear Manufacturing’s Next Chapter: Advanced Machining and the Role of Starrag in Clean Energy Innovation

With clean energy rising to the top of national and industrial agendas, nuclear manufacturing is proving essential to delivering secure, low-carbon power. Charles Carpenter, Head of Research at the University of Sheffield’s Advanced Manufacturing Research Centre (AMRC) nuclear group, stresses that nuclear must play a central role if the UK and other nations are to meet rapidly evolving energy needs—particularly those driven by AI, hyperscale data centres, and global decarbonisation targets.

As power demand accelerates, the industry faces an urgent question: can global manufacturing capacity meet the scale and speed needed to build the infrastructure required for new nuclear and other clean technologies?

Enter advanced manufacturing—and companies like Starrag, a leader in high-precision, large-part machining solutions. In the UK, Starrag has been instrumental in delivering world-class machining performance for nuclear applications through machines like its renowned Dörries CONTUMAT vertical turning lathe.

This ultra-heavyweight machine is purpose-built for the kind of large-diameter, high-integrity components used in nuclear power and other energy sectors. The CONTUMAT can handle enormous workpieces with micron-level precision—ideal for parts like nuclear pressure vessels, steam generators, and heavy flanges. Its multi-axis capability allows for turning, milling, and boring in a single setup, improving accuracy and drastically reducing lead times.

Technologies like this are becoming essential as the AMRC and its partners ramp up efforts to reduce nuclear vessel production times by 50% and costs by 40%. Projects with organisations such as the U.S. Department of Energy and the Electric Power Research Institute (EPRI) have already proven that it’s possible using methods like electron beam welding, diode laser cladding, and Hot Isostatic Pressing (HIP).

These capabilities are being brought together under one roof at the AMRC. The result? Full-scale demonstrator vessels combining cutting-edge machining, welding, and inspection, built to nuclear codes but using platforms applicable across petrochemical, hydrogen, and carbon capture sectors.

Crucially, Starrag’s large-part machining technology, like the Dörries CONTUMAT, is helping meet the growing need for ultra-precise, high-volume production of these components. And MTDCNC, a major media platform focused on advanced manufacturing, has covered numerous examples of Starrag’s role in enabling next-gen clean energy and aerospace applications—this nuclear application is just one powerful illustration.

But manufacturing innovation is only one part of the equation. The sector is already feeling the pinch from a shortage of skilled welders and machinists. Carpenter stresses the importance of training and upskilling both young talent and experienced workers from industries like steel, gas, and fossil fuels. These industries use the same materials and processes—creating a natural pipeline for the workforce needed in nuclear.

As the UK positions itself for leadership in clean energy, particularly through Small Modular Reactors (SMRs), the intersection of advanced machining, skills investment, and proven nuclear capability is more important than ever.

Carpenter concludes, “If we want to lead in data, AI, and clean energy, then our power sources must be affordable, resilient, and secure. Nuclear energy—enabled by advanced manufacturing technologies from companies like Starrag—isn’t just part of the solution; it’s the foundation for our future energy system.”