Manufacturing

Manufacturing plays a key role in delivering AWE’s mission to maintain and assure continuity of the UK’s nuclear weapon stockpile - a vital element of the overall defence strategy of the United Kingdom.

Manufacturing operations are undertaken in various facilities across both the Aldermaston and Burghfield sites. AWE’s manufacturing encompasses a diverse range of materials and processes including precision component manufacture, explosives formulation, fissile material production, rubbers and plastics, and warhead assembly and disassembly. The Manufacturing community also undertakes process technology development, material stewardship and supporting assurance services and manufacturing systems.

All manufacturing operations at AWE are undertaken with the strictest regard to the safety of all personnel, facilities, the local community and the environment. Highly trained production teams perform their operations in accordance with Facility Safety Cases and detailed Safe Systems of Work are employed to ensure that all hazards and risks are identified, assessed and eliminated or minimised to be ‘as low as reasonably practicable’ (ALARP).

Component manufacture is undertaken in support of the UK’s nuclear weapon stockpile, in addition to hydrodynamic trials and research and development programmes. Many of AWE’s manufacturing processes and materials present unique challenges that are not present within a conventional manufacturing environment. 

Some of the materials require specialised handling, processing and storage solutions due to their hazardous nature and many components are manufactured to very tight tolerances, from materials that are not easily formed or machined. This requires significant cutting-edge materials research and technology development, in order to manufacture and underwrite the components as safe and fit for purpose.

Nuclear Warheads are assembled and disassembled in purpose built facilities using dedicated suites of tooling and stringent working practices. In order to underwrite the continued safety and functionality of the UK nuclear deterrent, production areas across AWE also undertake surveillance activities involving processing and detailed forensic examination of components from disassembled nuclear warheads.

The manufacturing operations at AWE are supported by a range of specialist functions and systems including assurance, production planning, manufacturing engineering, tooling and container design and manufacture, materials development and facility management.