As a UK aluminium supplier with decades of experience, Simmal has witnessed aluminium’s role evolve from a basic structural metal into a high-tech linchpin for innovation. In 2025, three aluminium-driven advances are reshaping manufacturing in the UK and beyond. From the electric vehicle boom to aerospace 3D printing and next-generation smart materials, these innovations will change Britain’s businesses. Below, we explore each trend, why it matters, and where demand is heading, all from Simmal’s perspective as an industry expert.

Electrifying the Road: Aluminium Battery Enclosures for EVs

Electric vehicles are surging in the UK, and aluminium is literally at the base of this revolution – in the battery pack. Battery enclosures (the structural housings for EV battery cells) increasingly rely on aluminium for its lightweight and strength. The rationale is simple: EV batteries are heavy, so automakers offset that weight by using lightweight aluminium enclosures and frames, improving vehicle range and efficiency​. In fact, a recent study shows the average battery-electric car built in Europe contains around 283 kg of aluminium, versus 169 kg in a typical petrol car, and this is projected to rise to 310 kg by 2026​. Much of that aluminium goes into battery pack housings, crash-protective structures and cooling plates, highlighting how important aluminium has become for EV design​.

UK engineering expertise is contributing to better battery enclosures as well. A notable example is the £15 million ALIVE project, co-funded by the UK’s Advanced Propulsion Centre, which developed new aluminium-intensive EV battery enclosures with major automakers. The result? Innovative designs that cut enclosure weight by 12–35% compared to existing steel or older aluminium designs, without sacrificing strength​. Lighter battery boxes directly translate into longer driving range or the ability to add more battery capacity. This kind of R&D – happening on UK soil with companies like Constellium and Brunel University – shows where we’re headed: demand for advanced aluminium extrusions and alloys that make EV batteries safer, lighter, and more efficient. British EV startups and established carmakers alike are expected to specify more of these specialised aluminium components in their supply chains.

Additive Manufacturing: 3D-Printed Aluminium Lifts Off

In aerospace and high-end manufacturing, additive manufacturing (3D printing) with aluminium alloys is moving from prototyping to production. This innovation lets engineers “print” complex aluminium parts layer by layer, enabling designs that were impossible or too costly with traditional methods. For UK aerospace companies, 3D printing offers two big draws: lightweight complexity and speed. Parts with intricate internal lattices or topology-optimised shapes can be created to cut weight while maintaining strength – crucial for aircraft and satellites. Additionally, printing can drastically shorten production times for certain components. BAE Systems, for example, found that using 3D printing cut the production time of a large aircraft fuselage component from about two years to two months – a striking illustration of reduced lead time. When you consider the typical long lead times in aerospace supply chains, that speed is revolutionary. It’s no wonder BAE and others have put suppliers on notice that design and production methods are evolving; BAE even aims for 30% of its new Tempest fighter jet’s components to be additively manufactured in the coming years​.

Aluminium is a key material in this trend because of its prevalence in aerospace and automotive parts. High-strength printable aluminium alloys (like AlSi10Mg or Scalmalloy) are being used to produce everything from satellite brackets to drone airframes. The UK’s aerospace sector – including giants like Rolls-Royce and Airbus UK – is investing in additive manufacturing to remain competitive and flexible. Government strategy reflects this push too: the Ministry of Defence released its first Defence Additive Manufacturing Strategy in 2025, highlighting 3D printing as a means to strengthen supply chain resilience and enable on-demand production of parts​. For UK companies, this means the coming years will likely bring more 3D-printed aluminium parts in real-world use, not just test labs. We anticipate increasing enquiries about aluminium powders and specialised alloy stock for additive manufacturing, as well as design-for-AM consulting – a sign that this technology is maturing in practical applications.

Smarter, Stronger: Advanced Coatings and Aluminium Composites

The third innovation transforming manufacturing is less visible but equally significant: smart coatings and aluminium composites engineered for higher performance. In plain terms, researchers and companies are finding ways to make aluminium-based materials that are tougher, lighter, or more conductive by design – often by combining aluminium with other elements at the micro level.

One exciting development is graphene-enhanced aluminium composites. Graphene, a one-atom-thick carbon material, is famed for its strength and conductivity. When infused into aluminium, it creates a composite that retains aluminium’s low weight but dramatically boosts its properties. A UK company, Tirupati Graphite, recently developed a graphene-aluminium (Al-Gr) composite that showed significantly higher strength and electrical conductivity than conventional aluminium, to the point that it could even replace copper in certain applications​. This is a big deal – copper is heavy and expensive, so an aluminium-based substitute for things like busbars, power cables, or heat exchangers can interest many industries (from EV power systems to electronics cooling). We’re engaged in conversations with clients who are watching these developments: for instance, if you can use an aluminium composite that conducts electricity almost as well as copper, you might redesign electric motors or battery connections to save weight. The demand trend here is toward materials that do “double duty” – aluminium that isn’t just a structural skeleton, but also handles electrical or thermal tasks, simplifying the overall design. It’s about getting more performance per kilogram of material.

Aluminium is a platform for innovation. UK decision-makers who purchase aluminium should be aware of these three developments because they’re shaping what their competitors and customers will do next. Whether it’s lightweight battery trays for a new EV fleet, a 3D-printed aluminium tool that cuts a factory’s downtime, or a high-strength alloy that lets products leap ahead, the aluminium sector is evolving to meet those needs. By staying informed and working with expert suppliers, businesses can ride this wave of innovation safely – seizing the benefits while mitigating the risks. At Simmal, we’re here to provide not only material, but insight. The manufacturing landscape may be changing fast, but with aluminium’s adaptability and a clear view of industry trends, UK companies can confidently build the future.