Materials Technology
Maximising materials by embracing circularity across the entire value chain.
Pioneering innovative and sustainable solutions.
The pace of technological advancements is reshaping industries. However, this rapid progress brings with it significant challenges: materials are being extracted and consumed at unsustainable levels, increasingly pushed to their performance limits, and are facing increasing risks to their supply chains.
Engineers and researchers are faced with solving complex problems at pace, developing materials capable of withstanding extreme environments whilst delivering sustainable, energy-efficient solutions and enhancing resilience in materials supply chains.
MTC specialises in solid-state, net shape processes to manufacture complex, high-integrity, and sustainable components for demanding applications. Our expertise extends to material selection, process optimisation, and testing and validation. We promote circularity at a commercial production scale, supporting organisations that may lack the required expertise, facilities, time, or capacity for R&D work. Our team of experts also provides support and consultancy on broader materials challenges facing the UK industry, such as accelerating the transition to a hydrogen economy or promoting resilience in critical and strategic materials supply chains.
Providing end-to-end support within our state-of-the-art facilities, we can deliver evidence-based go / no-go decisions on market opportunities, and refine design, processes, costs, and performance for organisations of all sizes.
Materials Technology specialisms at MTC
Net Shape Technology refers to manufacturing and processing technologies that enable the production of components very close to their final shape, which minimises material waste by utilising the material where it is needed and reducing the need for additional machining or finishing steps.
MTC is one of the global leaders of net shape processing of complex, high-integrity components for the most demanding applications. Our expertise lies primarily in solid-state processes, where materials are processed below their melting temperature, thus reducing energy consumption and carbon footprint.
Our expertise covers a range of solid-state processes, such as:
Hot Isostatic Pressing (HIP)
The consolidation of metal powders by diffusion bonding into large-scale and high integrity net-shape components with uniform properties in all directions.
Cold Isostatic Pressing (CIP)
The partial compaction of powders into an intricate geometry prior to high temperature sintering to full density.
Cold Spray Additive Manufacturing (CSAM)
A highly controlled process of depositing and diffusing metal powder at supersonic speed. The impact causes particles to deform and instantaneously bond to the substrate. Very high deposition rates are achieved compared to conventional AM processes, enabling large parts to be built in minutes not hours.
Sinter-based AM
A mixture of powders and sacrificial binders is formulated into a feedstock and then printed in extrusion-based AM systems into a complex part. De-binding and sintering are used to remove the binder and fully consolidate the components.
Expert support
Our specialist capabilities in solid state processing benefit from the wider MTC expertise in design-for-X, modelling, simulation, metrology, and NDT.
We can support with:
Material selection and process optimisation for high-value applications, including aerospace, defence, civil nuclear, and hydrogen.
Design-for-manufacture, including modelling and validation.
Process cost-modelling and life-cycle assessment (LCA).
Materials testing and analysis, including mechanical testing and chemical analysis.
Joining of dissimilar materials using novel solid-state approaches that overcome challenges with difficult-to-weld materials.
Bespoke formulation capabilities for abrasive materials, composites, recycled waste and feedstocks for solid-state processing.
Specialist coatings for challenging in-service environments.
High / low temperature Hydrogen testing and bespoke equipment.
Heat treatment at high temperatures and bespoke environments, including vacuum, hydrogen, and inert gases.
Providing tailored training in our areas of expertise to address specific needs.
With the unique ability to produce low-risk demonstrators at production scale, we enable rapid optimisation of design, modelling, processing, cost, and performance.
Circular materials processing
Circular materials solutions focus on addressing circularity challenges throughout the whole material value chain rather than limiting the scope to end-of-life recycling. This includes developing and validating technologies to realise the reverse value chain, such as life extension, repair and remanufacture, and promoting methods that allow products to retain their value in service for as long as possible.
MTC helps organisations to optimise material lifecycles and reprocess commercial value by:
- Developing and demonstrating methods for value retention through repair, remanufacture and life extension.
- Exploring low-energy techniques for converting material waste into high value feedstock, demonstrating material symbiosis within high value manufacturing sectors.
- Designing, testing and inspection methods for end-of-life material assessment.
- Demonstrating scalable case studies to support industries on their net-zero journey.
Our work on circular materials benefits from MTC’s Digital Engineering capabilities, where digital tools are developed to enable circularity in materials value chain. Examples include developing material ‘passports’ for secondary materials or using predictive AI capabilities to increase visibility and assess risks in critical materials supply chains.
Materials technology consultancy
Materials analysis and consultancy leverages extensive knowledge and expertise developed over years of delivering materials innovation to high-value manufacturing sectors. The team’s strong academic foundation and wide-ranging industrial engagement across various sectors enable it to address broader materials challenges by providing specialised consultancy services that are independent, impartial and evidence based.
Our consultancy services include:
Technology scouting and roadmapping
Leveraging our extensive expertise and broad network of industrial and research partners, we conduct technology assessment studies and provide industry insights on new and emerging technologies, with a focus on materials processing and advanced manufacturing.
Materials circularity assessment
We conduct the Circular Materials Readiness Assessment (CMRA) using a tool developed and tested to evaluate circular materials challenges for businesses and identify opportunities for circular processing.
Supply chain resilience
Our services include mapping and assessing material value chains for critical and strategic materials. We focus on circular solutions to retain essential materials for strategic sectors such as aerospace, defence, and clean energy.
Materials lab
Specialising in powder characterisation and advanced metallurgy, offering detailed analysis and testing services and supporting technical standard organisations in developing and validating new standards.
Sparking progress with real-world solutions
MTC can support your materials technology goals by:
- Creating end-to-end solutions: Transforming ideas from idea to real-world application within our state-of-the-art facilities.
- Putting theory into practice: Bridging the gap between universities and industry to build on established research and deliver impactful industrial solutions.
- Providing specialist expertise: Our team holds substantial materials expertise, including rare expertise in powder metallurgy R&D.
- Reducing risk: Flexible workshop facilities and a wide range of the latest manufacturing equipment to enable low risk testing and scaling of new concepts.
Shaping the future of materials together.
At MTC, we combine cutting-edge expertise with advanced facilities to solve the most complex materials challenges. Whether you're looking to optimise performance, reduce waste, find your feet in sustainability, or build resilience into your supply chain, we’re here to help.
Beyond the materials, we’re passionate about developing future skills and driving cultural change. MTC Training offers accessible training to upskill workforces and increase industrial awareness.
Partner with us to unlock the full potential of materials technology and position your organisation for long-term success.