Zircotec

File:Plasma Spraying Process.jpg

Zircotec began life as part of the United Kingdom Atomic Energy Authority, where its high temperature coatings and heat barrier processes were originally developed for the nuclear industry. It was based at the Atomic Energy Research Establishment near Harwell, Oxfordshire. At the time, this was the main centre for atomic energy research and development in the United Kingdom.{{Cite web |url=http://www.zircotec.com/page/about_zircotec/203 |title= About Zircotec|access-date= 2013-04-23}}

In 1994, Zircotec's thermal barrier coatings were first used in a motorsport application. These coatings were applied to the exhaust systems of Subaru rally cars to lower in-cabin temperatures. After initial success, these high temperature coatings were then used on a variety of other vehicles, including Formula One cars and trucks.

Zircotec was bought by a venture capital fund in 2003. Subsequently, Zircotec shifted its focus from the nuclear industry, towards general industry and automotive applications. As a result, Zircotec developed Thermohold coatings for high performance automotive and classic car applications. Their main Thermohold coating was called Performance White, a white dual-layer plasma-sprayed ceramic.

In July 2007, Terry Graham was appointed as the new managing director.{{Cite web |url=http://www.zircotec.com/newsitem/3/5 |title= New Zircotec Managing Director|access-date= 2013-04-23}} Later that year, Koenigsegg, a Swedish automaker, announced use of Zircotec’s coatings on its CCX supercar.{{Cite web |url=http://www.autopresspoint.com/site.php?page=news&browse=true&p=82&|title= Autopresspoint.com news|access-date= 2013-04-24}} Additionally, in October, Zircotec became involved in the world land speed steam-car record attempt, supplying its coatings for thermal protection of sensitive components – this attempt was successful a year later.{{Cite web |url=http://www.ceramicindustry.com/articles/zircotec-to-supply-coatings-for-british-steam-car-challenge-posted-11-27-07 |title= Ceramic Industry News - Zircotec to supply coatings for British steam car challenge|access-date= 2013-04-23}}{{Cite news |url=http://news.bbc.co.uk/1/hi/8209288.stm |title= BBC News - UK team breaks steam car record|date= 25 August 2009|access-date= 2013-04-24}}

In June 2008, Zircotec developed a plasma-sprayed ceramic coating specifically for composite materials. Predominantly aimed at motorsport and high-performance car applications, coated composites could now function at temperatures above their melting points.{{cite web |title=Ceramic car coating (or glass coating) – 10 myths. |date=27 February 2019 |url=https://nano-zen.com/ceramic-car-coating-or-liquid-glass-coating-10-myths/}}

In September 2008, Zircotec launched its Performance Colours range. This range is based on Zircotec's Performance White coating, but has an additional coloured finish, offering a more robust and maintainable finish. Zircotec initially released thirteen different colours.

Zircotec's directors completed a management buyout early in 2009.{{Cite web |url=http://www.easier.com/4491-zircotec-completes-management-buy-out.html |title= Easier.com news – Zircotec completes management buy out|access-date= 2013-04-23}}

In 2010, the company's headquarters were relocated to the nearby town of Abingdon, Oxfordshire. The move was completed to provide increased production capacity and to accommodate future business growth.{{Cite web |url=http://www.zircotec.com/newsitem/3/68 |title= Zircotec acquires new production space at Abingdon, Oxfordshire|access-date= 2013-04-23}}

In 2011, Zircotec developed the world's first flexible ceramic heatshield, named Zircoflex.{{citation needed|date=October 2019}}

In July 2019, Zircotec experienced a fire at its premises and temporarily relocated to a nearby facility.{{Cite web |url=https://www.zircotec.com/zircotec-increase-capacity-ten-fold// |title=Zircotec moves into £2m premises |access-date= 2021-05-16}}

Zircotec announced an investment of £2.5m into a new 20,000 square foot premises in Abingdon which was completed by October 2019. This offers a ten-fold increase in capacity with a significant increase in workforce{{Cite web |url=https://www.zircotec.com/zircotec-increase-capacity-ten-fold// |title=Zircotec moves into £2m premises |access-date= 2021-05-16}}

In March 2021, the release of a new heatshield product – ZircoFlex SHIELD – was announced.{{Cite web |url=https://www.zircotec.com/new-heat-shield-technology-zircoflex-shield/ |title=Zircotec moves into £2m premises |access-date= 2021-05-16}}

In June 2022, Zircotec procured a further 10,000 square foot building which will be dedicated to producing technology for low and zero carbon vehicles.{{Cite web |title=Technology business expands to meet rising electric cars demand |date=27 June 2022 |url=https://www.oxfordmail.co.uk/news/20237753.abingdon-technology-business-expands-meet-electric-cars-demand/ |access-date= 2022-07-05}}

In 2024, Zircotec began leading the CeraBEV (Ceramics for Battery Electric Vehicles) project, a £1 million Advanced Propulsion Centre-funded collaboration with Cranfield University. The project aims to develop a single-layer ceramic coating that provides both dielectric insulation and flame resistance, enabling the use of lightweight materials such as aluminium and polymer composites in EV battery enclosures and cooling plates.{{Cite web |title=How ceramics can aid EV lightweighting |url=https://www.theengineer.co.uk/content/opinion/how-ceramics-can-aid-ev-lightweighting/ |website=The Engineer |date=8 April 2024 |access-date=2025-05-09}}

Zircotec develops thermal coatings and heat shielding materials for use in high-temperature environments.

Zircotec’s ceramic coatings are applied using a plasma spray process, where powdered ceramic material is melted in a high-temperature flame and sprayed onto a surface at high speed. The coating forms a thin, solid ceramic layer that reduces heat transfer from components such as exhausts and manifolds. A typical coating includes a metallic bond coat and a ceramic top layer, with a total thickness of around 300–350 microns. These coatings can lower surface temperatures by up to 25–33%, depending on the formulation:{{Cite web |title=Zircotec Products |url=https://zircotec.com/products/ |access-date=2025-05-09}}

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• Primary Range – a cost-effective option with moderate thermal protection
• Performance White – a higher-grade ceramic for more demanding environments
• Performance Colours – the same as Performance White, but with a coloured finish for appearance and easier cleaning.

These coatings are used in motorsport, automotive, and industrial applications to protect heat-sensitive components and enable the use of lightweight materials near high-temperature zones.{{Cite interview |last=Whyman |first=Peter |title=Advanced Ceramic Coatings In Motorsports |website=AZoM |date=2013-05-23 |url=https://www.azom.com/article.aspx?ArticleID=9527 |access-date=2025-05-23}}{{Cite web |title=Zircotec protects Europe’s fastest street legal drag car from the heat of competition |url=https://news.cision.com/propel-technology-ltd/r/zircotec-protects-europe-s-fastest-street-legal-drag-car-from-the-heat-of-competition,c9279901 |website=News.Cision.com |publisher=Propel Technology Ltd |date=2 July 2012 |access-date=23 May 2025}}

Zircotec’s flexible heat shields, branded as ZircoFlex, are thin, formable materials designed to provide thermal protection in confined or geometrically complex environments. The product combines a ceramic insulating layer with a metallic foil backing, allowing it to be bent, wrapped, or contoured without compromising its thermal performance. {{Cite web |title=Zircoflex heat shield |url=https://www.plasticstoday.com/automotive-mobility/new-heat-shield-technology-outperforms-conventional-products-in-lighter-package |access-date=2025-05-12}} ZircoFlex products are available in single-, double-, and triple-layer formats to suit different performance requirements. They are typically used in underbody panels, transmission tunnels, engine compartments, and other areas requiring compact and lightweight thermal solutions.

The original ZircoFlex material was launched in 2011 as the first commercially available flexible ceramic heat shield.[https://news.cision.com/propel-technology-ltd/r/zircoflex--provides-a-short-circuit-to-protection-for-brisca-f1-stock-cars,c9398916 "ZircoFlex provides a short circuit to protection for BriSCA F1 stock cars"]. Propel Technology Ltd. Retrieved 23 May 2025. It has since been used in a variety of sectors including motorsport, automotive engineering, aerospace, and offshore engineering. For example, ZircoFlex was employed to address overheating issues on an isolated oil platform in the Caspian Sea, where it was applied to HVAC systems to protect against radiant heat from a flare stack.[https://news.cision.com/propel-technology-ltd/r/flexible-ceramic-heatshield-solves-temperature-issues-at-isolated-caspian-sea-oil-platform,c9334568 "Flexible ceramic heatshield solves temperature issues at isolated Caspian Sea oil platform"]. Propel Technology Ltd. Retrieved 23 May 2025.

ZircoFlex SHIELD, a multi-layered, metallic-encapsulated heat shield system is designed for higher thermal loads. This product offers increased thermal attenuation compared to previous versions and is suitable for use in applications with continuous operating temperatures up to 1000 °C.[https://www.pmw-magazine.com/news/materials/zircotec-launches-new-heat-shield-material.html "Zircotec launches new heat shield material"]. Professional Motorsport World. Retrieved 23 May 2025.

Zircotec has developed plasma-sprayed ceramic coatings that enable fibre-reinforced polymers to withstand elevated temperatures, particularly in motorsport and high-performance applications.{{Cite web |title=A plasma-sprayed ceramic coating process shows promising potential for the composites industry |url=https://www.theengineer.co.uk/content/in-depth/surface-strength/ |access-date=2025-05-12}}

Its ThermoHold coating, first used in Formula One, was later applied to the Aston Martin One-77 to protect composite diffusers and intake ducts. The coating reduced surface temperatures by over 125 °C, enabling the use of lightweight materials near exhaust systems.{{Cite web |title=New Coating Lowers Composite Surface Temperature |url=https://www.pcimag.com/articles/97784-new-coating-lowers-composite-surface-temperature |website=PCI Magazine |date=1 May 2013 |access-date=2025-06-04}}

Zircotec also supplies ceramic thermal barrier coatings for CFRP wheels, particularly in motorsport and high-end road cars. The lightweight coating helps reduce heat transfer from brakes to the heat-sensitive rim, enabling the usage of CFRP.{{Cite web |title=Zircotec Provides Thermal Barrier Solutions for Wheels |url=https://zircotec.com/resources/news/zircotec-provides-thermal-barrier-solutions-for-wheels/ |date=15 December 2017 |access-date=2025-06-04}}

Zircotec develops ceramic-based thermal coatings for use in electric vehicle (EV) systems, with the aim of supporting thermal management, electrical insulation, and component protection in high-voltage environments. These coatings are intended to reduce the risk of thermal runaway, maintain optimal operating temperatures, and enable the use of lightweight materials in EV battery enclosures and cooling systems:{{Cite web |title=Zircotec to Use Ceramic Coatings in Electric Vehicle Battery Cases and Cooling Plates |url=https://www.powertraininternationalweb.com/components/zircotec-to-use-ceramic-coatings-in-electric-vehicle-battery-cases-and-cooling-plates/ |website=Powertrain International |access-date=2025-05-23}}

• ElectroHold Dielectric, which provides high dielectric strength (up to 42 kV/mm) while allowing thermal conductivity, enabling its use in battery housings, busbars, and power electronics.
• ElectroHold Flameproof, which offers short-term resistance to temperatures up to 1,400 °C and longer-term protection at lower temperatures, helping to delay or limit heat propagation in the event of a battery failure.
• ElectroHold EMC Shield, which is intended to reduce the effects of electromagnetic interference on sensitive electronic systems.

These coatings are compatible with various substrates, including aluminium, steel, and composite materials. Their application may support efforts to reduce vehicle weight without compromising functional or safety requirements.{{Cite web |title=Zircotec to lead vital ceramic coating research to enable lightweight material use in electric vehicle battery enclosures and cooling plates |url=https://zircotec.com/resources/news/zircotec-to-lead-vital-ceramic-coating-research-to-enable-lightweight-material-use-in-electric-vehicle-battery-enclosures-and-cooling-plates/ |website=Zircotec |access-date=2025-05-23}}

These developments form part of the CeraBEV (Ceramics for Battery Electric Vehicles) project, a UK government-supported initiative led by Zircotec in collaboration with Cranfield University. The project aims to develop coatings that enable the wider use of lightweight materials while meeting the safety and performance requirements of EV battery and cooling system design.{{Cite web |title=How ceramics can aid EV lightweighting |url=https://www.theengineer.co.uk/content/opinion/how-ceramics-can-aid-ev-lightweighting/ |website=The Engineer |date=8 April 2024 |access-date=2025-05-09}}

Zircotec works closely with motorsport teams from various categories, including Formula One, the British Touring Car Championship and NASCAR.

Since 2018, Zircotec has maintained a technical partnership with Power Maxed Racing.{{Cite web |url=https://www.zircotec.com/category/pmr/ |title=Power Maxed Racing |access-date= 2021-05-16}}

• Aston Martin Valkyrie{{Cite web |url=https://www.zircotec.com/zircotec-has-aston-martins-back/ |title=Aston Martin Valkyrie |access-date= 2021-05-16}}
• Aston Martin One-77{{Cite web |url=https://www.zircotec.com/a-look-back-at-the-aston-martin-one-77/ |title=Aston Martin one-77 |access-date= 2021-05-16}}
• Ducati Diavel Diesel{{Cite web |url=https://www.zircotec.com/zircotec-motorcycle-exhaust-ceramic-coating/ |title=Ducati Diavel Diesel |access-date= 2021-05-16}}
• Lamborghini Murciélago
• Koenigsegg CCX
• Pagani Zonda{{Cite web |url=https://zircotec.com/products/|title=Zircotec Products|access-date=2024-04-18}}
• New Holland Low Carbon Gas Tractor{{Cite web|title=» CNH – LoCT|date=9 September 2021 |url=https://www.apcuk.co.uk/funded-projects/cnh-loct/|access-date=2021-11-02|language=en-GB}}{{Cite web |url=https://www.apcuk.co.uk/news/new-holland-unveils-the-first-pre-development-of-its-low-carbon-tractor-at-low-carbon-vehicle-event-2019/|title=Low carbon gas tractor |date=4 September 2019 |access-date= 2021-05-16}}

Zircotec undertakes research and development in collaboration with OEMs, universities, and publicly funded programmes, including the Advanced Propulsion Centre (APC) and Innovate UK. Its work focuses on thermal management for hydrogen engines, fuel cells, and electric vehicles, including coatings to reduce hydrogen embrittlement and support alternative-fuel applications.

Zircotec contributed ceramic coatings to APC-18 (Project Brunel), a collaboration with Cummins, Johnson Matthey, and PHINIA aimed at developing a 6.7-litre hydrogen-fuelled engine for commercial vehicles.{{cite web |title=Zircotec's advanced coating technology drives success in APC-18 project |url=https://www.globallogistics.co.uk/zircotecs-advanced-coating-technology-drives-success-in-apc-18-project/ |website=Global Logistics |access-date=29 May 2025}} The project demonstrated the potential for hydrogen combustion in heavy-duty applications.{{cite web |title=Cummins Brunel |url=https://www.apcuk.co.uk/impact/funded-projects/cummins-brunel/ |access-date=12 May 2025}}

Zircotec also leads CeraBEV, a £1 million project with Cranfield University to develop ceramic coatings combining dielectric insulation and flame resistance for use in battery electric vehicle enclosures and cooling systems.{{cite web |title=How ceramics can aid EV lightweighting |url=https://www.theengineer.co.uk/content/opinion/how-ceramics-can-aid-ev-lightweighting/ |website=The Engineer |date=8 April 2024 |access-date=9 May 2025}}

File:Plasma sprayed dual layer coating optical microscopy.jpg

The company operates a laboratory in Abingdon equipped for high-temperature testing, thermal imaging, microstructural analysis, and mechanical and dielectric testing. External partners support additional testing, including hydrogen permeation and electromagnetic interference (EMI) analysis. The lab supports product development and quality control, underpinned by a long-term archive of coating data.{{cite web |title=R&D facility rises to challenge of high-temperature exhausts |url=https://www.theengineer.co.uk/content/advanced-manufacturing/rd-facility-rises-to-challenge-of-high-temperature-exhausts |website=The Engineer |access-date=29 May 2025}}

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