Engineering
Keeping the Lights on in High Level Waste Plants
About the client
Sellafield Ltd is responsible for the safe and secure management of one of the world's most complex nuclear sites. As a mission-led organisation, it decommissions high-hazard facilities, manages nuclear materials, and delivers environmental remediation that protects people and the planet.
Operating on behalf of the Nuclear Decommissioning Authority (NDA), Sellafield plays a critical national role in addressing the UK’s nuclear legacy. The organisation delivers this mission through programme management, engineering oversight, stakeholder engagement, and supply chain coordination—supported by a long-term commitment to safety, value for money, and social impact.
📍 Sellafield, UK
💼 Nuclear
⚙️ P3 Management
Challenge
Critical Shortage of Bespoke Nuclear Lamp Holders
A bespoke lamp holder, critical for illuminating nuclear process cells in the High Level Waste Plants, was at risk of running out after the original supplier ceased trading. With spares running critically low, there was a growing risk of disruption to essential inspection and maintenance activities in a high-hazard environment. A fast, reliable, and compliant replacement was needed to maintain safe operations.
Solution
Reverse Engineered Solution with Additive Manufacturing Upgrade
The team undertook a full reverse engineering of the lamp holder assembly to recreate the component without access to original manufacturing drawings. The design was carefully measured, modelled, and validated to ensure it matched the fit, function, and performance of the original part.
To restore supply quickly and improve resilience, the previous injection-moulded main body was replaced with an Additive Manufacturing (AM) alternative. This approach eliminated the need for expensive tooling, reduced lead times, and allowed for on-demand production of spares. Material selection and print parameters were optimised to meet the mechanical, thermal, and chemical resistance requirements of the nuclear environment, and the final part was subject to quality checks to confirm suitability for deployment.
Process
Development process steps
The development process starts with Material analysis and recommendation from SL Polymer CoE, conducted by the Plant-Facing Design Office. This is followed by Prototyping and design refinement at Engineering CoE, focusing on innovative solutions. Next, Manufacturing a polymer by a qualified high-grade polymer supplier with decades of AM experience ensures quality production. The process then moves to Full component assembly and testing by local supply chain, ensuring integration and functionality. Finally, the product reaches Deployment, marking its operational use.
Benefits
Risk Eliminated, Costs Reduced, and AM Successfully Deployed
Delivery of this alternative solution eliminated the risk of running out of spares and impacting production throughput.
The new lamp holder assembly is supplied at a lower cost than the original.
Successful deployment of a QG03 additively manufactured item to site.
