Supporting the Defence supply chain: sub-contract welding & fabrication UK

The Defence supply chain in the UK is made up of various tiers, from the major Prime contractors such as BAE Systems and Babcock to the network of SMEs which support them in delivering programs for the MOD. This includes a significant number of companies who provide sub-contract welding and fabrication in the UK.

In an interview with Defence Contracts International (DCI), Make UK Defence Director General Andrew Kinniburgh estimated that current UK Defence spend with SMEs is at around 20%, compared to 40% in the US. There is a real opportunity for the Defence sector in the UK to take advantage of the responsiveness and agility of SMEs to solve problems and deliver solutions at pace.

The Defence Industrial Strategy sets out a £250 million investment aspiration, bringing together military, industry and academia and making the road clearer and more straightforward for SMEs to do business with the MOD. This will improve the UK’s resilience and make it easier for the MOD and primes to harness the innovation that SMEs can deliver.

Why sub-contract welding and fabrication matters for UK Defence

The government estimates that the Defence industry contributes between £10 billion – £15 billion per year to the UK economy, of which approximately 4% was through SMEs.

Defence manufacturing often requires bespoke, intricate and mission-critical components for applications such as land systems, naval structures and weapons systems.

While Defence primes will liaise with the MOD on the design and product requirements of these systems, it falls to SMEs specialising in specific areas of expertise to take the generated engineering drawings and ensure they can be scaled effectively, efficiently and economically. For example, this might mean using Design for Manufacturing expertise to assess and adjust weld in a product to make it both sturdier and easier to fabricate, as was the case with the Tactica vehicles for BAE Systems.

Using sub-contract welding and fabrication specialists helps to maintain agility in the procurement process, through bridging gaps in capability of the larger suppliers and primes.

How can design changes reduce weld time and overall project cost? 

Design changes can impact weld time and project cost in various ways.

The most important first step is to ensure you have a through Design for Manufacturing review with your nominated specialist subcontractor. They work with metal day in and day out and will have many years’ experience in what works and doesn’t, and why. A Design for Manufacturing review will consider elements such as:

• The number and location of welds
• The number, location and angle of folds in the metal
• Specified tolerances
• Material choice
• The selected fixtures and fittings and whether these are a) suitable and b) easily accessible
• The overall design drawings and whether these are detailed enough for a Production and Assembly environment

Thoroughly reviewing and implementing recommended design changes ensures an economical and repeatable final product.

What certifications should a sheet metal welding supplier hold in the UK?

While there is a plethora of different accreditations that a subcontract welding and fabrication company could hold, there are some key ones which indicate quality and expertise:

• ISO 9001:2015 – a Quality Management System accreditation that ensures a company can consistently provide products that meet customer, statutory, and regulatory requirements. Key areas assessed include Leadership & Commitment, Planning, Evaluation and Improvement.
• DIN 2303 Q2/BK1 – DIN 2303 is a German standard which outlines the quality requirements for welding for military applications. BK1 is the highest classification in the standard, relating to products with the greatest criticality. While very common in Germany, within the UK there are only around 15 sheet metal fabrication companies – including Universal Wolf – who hold this standard.
• ISO 3834 – ISO 3834 assesses a sheet metal fabricator’s quality management system specifically related to welding. It considers things such as the presence of a Responsible Welding Coordinator, valid certifications for welders, technical reviews and procedures and equipment maintenance and calibration.
• CSWIP – The Certification Scheme for Welding Inspection Personnel. This is a globally recognised certification for professionals in welding, fabrication and inspection. It validates the skills, experience and knowledge of a welder/fabricator.

This is a good place to start when you are looking for a sub-contract welding & fabrication supplier in the UK. These accreditations demonstrate quality, traceability, and risk control.

How is weld quality inspected and documented for traceability?

At Universal Wolf, weld quality for Defence projects is managed through a fully traceable inspection and documentation process. This is aligned to key standards ISO 3834-2, DIN 2303 Q2/BK1 and any customer-specific requirements.

Welding is carried out by welders who are qualified to ISO 9606-1 and ISO 9606-2 – qualification tests for the welding of steel and aluminium/aluminium alloys respectively.

Inspection

Weld quality inspection is carried out by both CSWIP 3.0 qualified welding inspectors and the Responsible Welding Coordinator (RWC). It happens at key, pre-defined points such as:

• Pre-weld
• In-process
• Final inspection

Inspection can be visual, aligned to ISO 17637, or can take the form of non-destructive testing (NDT) where specified by the customer. This is completed using approved procedures and providers. Examples of NDT include:

• Dye penetrant
• Magnetic particle inspection

Traceability

Traceability for Defence contracts is comprehensive. Each weld is recorded in a controlled Weld Log which links the weld to:

• The component
• The drawing reference
• Welding Procedure Specifications (WPS)
• Welder identification
• Material certificates
• Consumables
• Inspection results
• NDT records where applicable

The above information is pulled together into a project-specific inspection pack, which is reviewed internally before being passed over to the customer.

In conclusion

The sub-contract welding & fabrication UK supply chain is a critical part of the overall MOD procurement framework. Facilitating access for SMEs to work more closely with MOD supply chains will provide access to continuous improvement and innovation, supporting the government’s ambitions to make Defence an engine for growth.

Are you looking for a sub-contract welding and fabrication partner for your Defence project? Complete our contact form and a member of the team will get in touch!