When we first developed the proposal for DER-IC in 2019, our focus was on building a national network that would drive innovation in Power Electronics, Machines, and Drives (PEMD) manufacturing, enabling the UK to remain competitive in an increasingly electrified future. Little did we know how the world would then change. From Brexit to the pandemic, supply chain disruptions, and widespread labour shortages, the manufacturing sector was thrown into a period of dealing with immense uncertainty and insurmountable need.
The ambition and potential for electrification and industrial transformation was kicked into high gear. Now it was not only an exciting opportunity to steer us toward our Net Zero goals, but also to support businesses who needed solutions fast in the face of supply chain shutdowns and project delays.
It was in this climate that DER-IC officially launched, not just as a research and innovation network, but as a necessary vehicle for rebuilding resilience in UK manufacturing. In the time since, DER-IC has played a pivotal role in facilitating advancements in electrification, enabling companies to scale manufacturing capabilities and transition towards net zero.
In a UK-first, through our network of over 30 Universities and Research and Technology Organisations (RTOs), we have offered manufacturers access to cutting-edge facilities, expertise, and collaboration opportunities to de-risk investment, accelerate innovation, and build a robust UK-based PEMD supply chain.
Largely, we’ve stepped out of the immediate mire of a number of years of persistent headwinds and emerged in a new era of manufacturing. Collaborations, shared knowledge, skill and open-access equipment have enabled us to deliver some significant progress. We’ve created a legacy, which we will continue to add to, but is something to be proud of. As I look to the future, which includes some downtime to enjoy my retirement, I’d like to indulge in some of the achievements of DER-IC and experts within it and the impact on electrification.
Designing for sustainability and opportunity: H2GEAR
Developing an advanced PEMD manufacturing sector requires precision in both product design and manufacturing process development. DER-IC provides expertise in optimising the design of power electronics, electric machines, and drives to ensure efficiency, sustainability, and manufacturability at scale.
The H2GEAR programme involved leading academics at Newcastle University’s School of Engineering, led by GKN Aerospace. It will be at the heart of the technological developments needed for the future of more sustainable aviation.
The programme had access to DER-IC equipment, including a power electronics assembly line and a flexible electric machines assembly line. The Newcastle University team used their understanding of electronic materials, power electronics and electrical power networks to develop an ultra-high efficiency power and propulsion system that will provide the backbone of this advanced technology.
The programme has developed a cryogenically enhanced propulsion system for short-distance aircraft that could be scaled to larger aircraft. Liquid hydrogen is converted to electricity within a fuel cell system, which efficiently powers the aircraft and eliminates all harmful CO2 emissions.
H2GEAR is creating a new generation of clean air travel and reinforce the UK’s position at the forefront of aerospace technology research and development. Newcastle University’s collaboration with GKN Aerospace, Intelligent Energy, Aeristech, University of Manchester and University of Birmingham is expected to create more than 3,000 jobs in the next decade.
Scaling UK PEMD capabilities: The UK-ALUMOTOR Project
Scaling PEMD manufacturing in the UK hinges on the ability to develop sustainable, high-performance electric motors while strengthening domestic supply chains. Recognising this, The Ricardo UK-Alumotor project received two phases of funding from the UKRI Driving the Electric Revolution Challenge fund. A consortium of key industry partners was formed to develop the UK’s electric motor supply chain by leveraging its manufacturing expertise to deliver the next generation of sustainable electric motors. DER-IC network partner Warwick Manufacturing Group (WMG) was part of the consortium along with Ricardo, Aspire Engineering, Brandauer, Phoenix Scientific Industries and Global Technologies Racing.
Throughout the project, the partners identified and developed preferred manufacturing processes which are suitable for volume production of the patented motor design from a UK supply chain, whilst refining the design to meet the future requirements of their UK and international stakeholders. The project supported the UK’s net zero ambitions by developing a more affordable, environmentally sustainable design which displaces the need for scarce material resources, resulting in a greener and more affordable solution to support the mass adoption of electrification. Training the next generation was also a focus and UK-Alumotor was committed to growing the UK’s PEMD manufacturing capability and training the next generation of skilled engineers and technicians, positioning the country at the forefront of the global electric revolution.
Material innovation: Centre of Integrative Semiconductor Materials
Material selection is fundamental to PEMD technology performance. DER-IC provides advanced facilities for analysing and evaluating materials, components, and joining technologies, ensuring optimal material use and performance.
The Centre for Integrative Semiconductor Materials (CISM) at Swansea University has become a pillar of next-generation semiconductor research and manufacturing, addressing the UK’s need for a resilient domestic supply chain. The CISM has received a £5m investment from DER to create a wide band gap power electronics component industrial pilot line. The pilot line will also be part of CSconnected, the world’s first compound semiconductor cluster based in South Wales. The new equipment will be housed in CISM at Swansea University’s Bay Campus in bespoke ISO 5 and 6 Cleanrooms.
With DER-IC’s support, CISM is driving industrial-scale innovation, securing the UK’s position as a leader in high-performance semiconductor manufacturing.
Bridging the gap: prototype manufacture and scale-up support
The APC funded @FutureBev project, which partnered with us at the University of Warwick to test a new power inverter in the power electronics module assembly, reliability and failure analysis facility. This equipment was commissioned just in time to support the @FutureBev project, which was completed in April 2024, and involved six partners including DER-IC, University of Warwick and CSA Catapult.
The inverter testing project marked a new chapter for this supply chain. Car manufacturers have previously been testing inverters with motors in high-cost dynamometer facilities that needed to contain high-speed equipment failures. The DER-IC facility, created with input from academic specialists and using a Hardware in Loop approach, is smaller, less costly, easier to access, and can be applied in other sectors. The @FutureBev project used this new equipment to test components in isolation, i.e. the inverter, without the motor itself.
All the partners have benefitted from this project, and one, Custom Interconnect, has built new automotive sector business and invested in new manufacturing capacity.
By providing prototype validation, process optimisation, and scalable test environments, DER-IC ensures that UK manufacturers can refine designs, validate performance, and confidently scale up production, reinforcing the UK’s position in electrification and PEMD supply chains.
Building skills for electrification: workforce development
The UK has long been a global leader in research and development, with cutting-edge facilities and expertise driving innovation. However, there exists a barrier in translating this knowledge into industrial-scale application within PEMD.
For PEMD to thrive, industry and academia must collaborate more closely, ensuring that innovation moves seamlessly from the research lab to commercial deployment, something which DER-IC has been proud to facilitate. The Warwick Electrification Deployment (WELD) project, supported by DER-IC and the High Value Manufacturing Catapult, is a prime example of this approach in action.
By establishing a new Winding Centre of Excellence at WMG, WELD has provided UK-based OEMs and SMEs with hands-on training in advanced eMachine manufacturing techniques. The project focuses on upskilling engineers and technicians in power electronics, electric machines, and advanced manufacturing, equipping them with the expertise needed to develop and scale next-generation electrification technologies.
With 80% of the 2030 workforce already in employment, reskilling and knowledge transfer are crucial. We need to ensure a dynamic exchange exists between industry and academia, with initiatives like WELD to ensure that the UK’s PEMD sector is equipped to compete globally, drive economic growth, and meet the demands of a net-zero future.
Robin Thamarasseril George, Facility Engineer, Winding Centre of Excellence
What’s next for the future of PEMD manufacturing and DER-IC?
As the UK continues its journey towards net zero, DER-IC will remain both a lynchpin and catalyst within the national PEMD manufacturing ecosystem. The UK’s industrial trajectory is at a pivotal moment, with Invest 2035 outlining a long-term vision to position the country as a global leader in advanced manufacturing and clean energy industries. This strategy recognises that sustainable growth will depend on fostering innovation, strengthening supply chains, and investing in people and skills—all of which align with the mission of DER-IC.
PEMD is central to delivering the next generation of electrification technologies, supporting industries from transport and renewable energy to automation and digital infrastructure. As government and industry seek to capitalise on high-growth sectors, it is critical that PEMD is recognised as a foundational enabler of economic transformation.
By bridging academic research with industrial application, DER-IC will continue to de-risk new technologies, accelerate commercialisation, and scale up UK-based manufacturing. With the right policy support, investment, and collaboration, PEMD will be a driving force in ensuring the UK’s competitiveness.
Looking ahead, DER-IC’s focus will be on strengthening industry collaboration from the network of centres to deliver, scale and democratise next-generation PEMD technologies, and support OEMs in bringing more production back to the UK. By embedding PEMD technologies into the government’s Industrial Strategy, DER-IC can ensure that the UK remains at the forefront of the global electrification race.
DER-IC’s legacy and its continued delivery will be defined by the strength and sustainability of the UK’s PEMD supply chain, an objective which will persist for years, even decades to come.
Stepping away, I feel confident that the foundations have been laid for the UK to emerge as a world leader in PEMD manufacturing.
To find out more and to work with DER-IC, visit www.der-ic.org.uk
Professor Michael Capaldi, Chair of DER-IC
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