Tungsten, niobium, and tantalum, the metals that will define the next generation of energy and defence technology, share a common challenge: they are notoriously difficult to process and largely sourced from geopolitically sensitive regions.
As the UK moves to reduce its dependence on foreign supply chains for strategic materials, Loughborough University is tackling both problems at once, using electron beam technology (EBM) to process these materials domestically in ways that conventional platforms cannot.
The Limits of Laser and the Case for EBM
A decade and a half spent pushing laser-based systems to their limits has given Professor Attallah a precise understanding of what those systems cannot do. Certain metals, copper, tungsten, tantalum, molybdenum, and niobium, present physical obstacles that laser processing struggles to overcome: some are too reflective, others demand temperatures beyond practical thresholds, and several react destructively when exposed to atmospheric conditions.
EBM addresses many of these barriers by confining the process to a vacuum environment, eliminating atmospheric interference for oxygen-reactive materials while generating the power density needed for metals at the extreme end of the processing spectrum. These characteristics make it a natural fit for energy, aerospace, and defence applications where material performance is non-negotiable.
What made Freemelt’s platform compelling for Loughborough was not only its technical capability but the degree of control it places in researchers’ hands. Unlike closed industrial systems, it allows direct modification of process variables, testing of non-standard alloys, and development of entirely new workflows.
“Electron beam technology succeeds where other additive techniques have struggled,” said Professor Attallah. “The Freemelt system stands out by being open, flexible, and accessible for researchers. It allows us to experiment with parameters, explore new alloys, and develop processes that are impossible on closed commercial platforms.”
The open architecture also positions the platform for integration with machine learning-driven optimisation, compressing material qualification timelines, widening the range of viable alloys, and improving build consistency as requirements evolve.
From the Lab to the Frontier
That freedom is already producing results. Active projects include tungsten component development for nuclear fusion infrastructure with Tokamak Energy and Metamorphic, niobium-based material research for spacecraft propulsion, and a UK–Japan collaboration coordinated by the University of Birmingham examining refractory alloy behaviour and oxygen uptake during additive processing.
“If we want to build nuclear fusion reactors or next-generation spacecraft, we need sustainable manufacturing methods for critical materials,” said Professor Attallah. “EBM not only enables this but also offers the scalability and efficiency to make it viable.”
The UK’s Critical Materials Moment
The work underway at Loughborough does not exist in a vacuum. Across government and industry, the question of how the UK sources, processes, and retains control over critical materials has moved from a policy footnote to a strategic priority.
In April 2025, the Ministry of Defence published its first Defence Advanced Manufacturing Strategy, identifying additive manufacturing as a key pillar of the British military’s long-term planning and emphasising its role in strengthening supply chain resilience. The financial case is documented: a Defence Innovation Unit report estimated that 3D printing 15% of the UK’s defence inventory could save £110 million over the next 15 years, with annual net benefits potentially reaching £35.5 million thereafter.
The MoD has translated policy into concrete programmes. Project TAMPA is establishing a multi-supplier framework capable of producing stronger, lighter metal parts at the point of need, a direct response to supply chain fragility exposed by ongoing global conflicts. Additive manufacturing is also being applied to the UK’s nuclear submarine programmes, including In Service Submarines and the SSN(A) programme, while the Atomic Weapons Establishment uses the technology to produce complex components.
Loughborough’s adoption of the Freemelt system adds to an expanding base of UK academic and industrial users, reinforcing the country’s standing in advanced materials research.
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Featured image shows Professor Moataz Attallah (left) and Mohamed Said – service technician at Freemelt. Photo via Freemelt.
