Engineering
Reversing Obsolescence in the UK’s Alpha Monitors
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
High Cost of Obsolescence in Nuclear Air Monitoring Systems
The global nuclear industry relies on Particulate in Air Monitors to protect worker safety across operational sites. However, as key components become obsolete, replacing an entire monitor can cost up to £20,000. With 3,000–4,000 units in use at Sellafield alone, sourcing and qualifying replacement parts is essential to avoid expensive full-unit replacements.
This project remains in active development, with work ongoing to finalise and implement the solution. While not yet complete, it is a significant part of our portfolio, reflecting our commitment to tackling high-value obsolescence challenges in the nuclear sector.
Solution
Extending Equipment Life Through AM-Optimised Reverse Engineering
We have reverse-engineered the obsolete component, capturing precise dimensions, functional requirements, and material properties to ensure compatibility with existing monitor assemblies. The redesign retains the original performance characteristics while introducing modifications to optimise the part for additive manufacturing.
This AM-ready design will allow the customer to produce the component in small batches, reducing reliance on a fragile supply chain and extending the operational life of the monitors. The project is still in progress, with final testing, validation, and implementation planning underway. Once complete, this approach will provide a flexible, cost-effective route to replace obsolete parts and avoid the need for costly full-unit replacements.
Process
End-to-End Spare Part Development and Validation Proces
The required spare part is first assessed for manufacturing feasibility, including material selection, dimensional accuracy, and performance requirements. Once confirmed, the part is designed using precise engineering data, then prototyped to ensure it meets fit and functional needs.
Following successful prototyping, the component is deployed for on-site testing and validation under operational conditions. Throughout the process, a comprehensive technical file is compiled to document design, manufacture, and quality assurance. Upon completion, a Certificate of Conformity is issued to confirm the part meets the required standards for nuclear use.
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.
