BAE Systems has developed innovative new approaches to the production of energetics and propellants, aimed at enhancing supply chain resilience for the UK and its allies.

These developments follow more than £150 million of investment by the company in its UK munitions facilities since 2022. This investment will result in a sixteen-fold increase in the production capacity of 155mm artillery shells once its new explosive filling facility at Glascoed, South Wales, becomes operational this summer.

An additional £8.5 million has been invested over the past five years in novel manufacturing methods, leading to significant breakthroughs in the development of next-generation explosives and propellants.

These new methods utilise continuous flow processing to synthesise explosive materials, eliminating the need for nitrocellulose and nitroglycerine—two substances that are in high demand globally—in propellant production.

As a result, the company expects to produce sufficient explosives and propellants domestically to meet the requirements of the UK Ministry of Defence and export markets, with the initial phase of industrial capacity anticipated by the end of 2026.

A pilot programme has already demonstrated the technological breakthrough, producing explosives in small nodes. This approach could negate the need for a large-scale explosives factory. The new propellant formulation and its associated manufacturing process have been demonstrated across a wide spectrum of products, from small arms to large-calibre munitions.

These technologies are designed to require lower capital investment and offer significantly reduced operational costs, while also improving safety during manufacture. The continuous process ensures that only minimal amounts of explosive material are handled at any given time.

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In addition, BAE Systems will present a broad range of defence and security solutions for land, sea, and air at the Defence Exhibition Athens (DEFEA) 2025, taking place at the Metropolitan Expo from 6–8 May (Hall 4, Stand A6).

The event will showcase BAE Systems’ strategic international partnerships alongside both proven and emerging technologies. For decades, BAE Systems and Greece have collaborated to provide defence solutions in support of Greece and its allies.

BAE Systems will exhibit the full breadth of its capabilities, including the CV90, Bradley Fighting Vehicle, Amphibious Combat Vehicle, Hypervelocity Projectile, naval ship solutions, and comprehensive training and sustainment support for these and other platforms.

Working with partners in Greece, Europe, and across the globe, BAE Systems delivers advanced defence technologies that contribute to national security, safeguard critical infrastructure and information, and promote economic development.

With a workforce of over 100,000 across more than 40 countries, the company continues to pioneer innovative solutions that provide customers with a strategic edge across the air, maritime, land, and cyber domains.

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