Engineering
Reversing Obsolescence in the
UK’s Alpha Monitors
About the client
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📍 Location UK
💼 Industry
⚙️ Innovation Management
Co-Lab has consistently delivered these projects in a structured and organised manner, keeping teams engaged, motivated, and results driven.
- Viv Winter, Head of Business Improvements, Sellafield Ltd, Legacy Ponds
Challenges
High Cost of Obsolescence in Nuclear Air Monitoring Systems
The global nuclear industry ensures worker safety by deploying Particulate in Air Monitors across various sites. However, as components become obsolete, replacing an entire monitor can cost up to £20,000. With 3,000–4,000 units in use at Sellafield alone, finding replacement parts is crucial to avoiding costly full-unit replacements.
Solution
Extending Equipment Life Through AM-Optimised Reverse Engineering
We reverse-engineered the obsolete component and optimised its design for additive manufacturing, allowing the customer to produce small batches and extend the monitors' lifespan.
Process
End-to-End Spare Part Development and Validation Proces
The required spare is assessed for manufacturing feasibility, then designed, prototyped, and deployed for testing and validation. A technical file is compiled, and a Certificate of Conformity is issued.
Benefits
Significant Cost Savings and Extended Equipment Lifespan
Cost Savings – Avoids full monitor replacements, saving up to £20,000 per unit, potentially reducing costs by millions across Sellafield and similar sites.
Extended Equipment Lifespan – Enables continued use of existing Particulate in Air Monitors, preventing premature obsolescence.
Rapid Replacement of Obsolete Parts – Reverse engineering and additive manufacturing provide fast, on-demand production, reducing downtime.
