Zircotec

Zircotec is a United Kingdom-based materials-technology company specializing in high-temperature ceramic coatings and heat-barrier systems. The business is headquartered in Abingdon, Oxfordshire, near the Harwell science and engineering cluster. Its core technology uses plasma spraying: powdered ceramic material is melted in a high-temperature flame and deposited at high speed onto a component, producing a thin, durable ceramic layer that can reduce heat transfer, protect substrates, and improve resistance to abrasion and harsh operating conditions. The technology originated within the United Kingdom Atomic Energy Authority and the Atomic Energy Research Establishment at Harwell. It was initially developed for demanding nuclear-industry environments rather than as an automotive consumer product. A major early commercial application came in 1994, when the coatings were used on Subaru rally-car exhaust systems to reduce heat entering the vehicle cabin. The technology subsequently spread into other motorsport categories, including Formula One, as well as trucks and specialist vehicles. Following a 2003 acquisition by a venture-capital fund, the business shifted its emphasis away from nuclear-sector work and toward general industry, automotive engineering, and performance vehicles. Its Thermohold thermal-barrier coatings became associated with high-performance and classic-car applications. The Performance White product was later joined by Performance Colours, a range that combined ceramic thermal protection with a coloured finish intended to improve appearance, cleaning, and maintenance. Zircotec coatings have been associated with components used by vehicle manufacturers and specialist engineering companies, including exhausts, manifolds, composite diffusers, intake ducts, wheels, and other parts exposed to high radiant or conductive heat. The company broadened its technology platform beyond rigid coatings with the development of ZircoFlex, described as a flexible ceramic heat shield. Introduced in 2011, ZircoFlex combines a ceramic insulating layer with metallic foil and can be bent or formed around confined spaces. Single-, double-, and triple-layer versions address different thermal loads. A subsequent product, ZircoFlex SHIELD, uses a more heavily encapsulated multilayer construction for higher-temperature applications. These systems have been marketed for engine compartments, underbody panels, transmission tunnels, industrial equipment, offshore installations, and other environments in which conventional rigid insulation is difficult to install. Zircotec also develops coatings for composite materials. These systems are intended to allow carbon-fibre-reinforced polymers and other lightweight substrates to operate near hot exhaust, braking, or engine components. Reported applications include motorsport parts, high-performance road cars, composite diffusers, intake ducts, and carbon-fibre wheels. The company has supplied or supported applications connected with vehicles such as the Aston Martin One-77 and Valkyrie, Koenigsegg CCX, Pagani Zonda, Lamborghini Murciélago, and Ducati Diavel Diesel, although the precise commercial relationship varies by application. In more recent years, Zircotec has expanded into thermal-management and protection technologies for low- and zero-carbon powertrains. Its development work includes ceramic systems intended to provide thermal insulation, dielectric protection, flame resistance, electromagnetic shielding, and substrate protection in electric-vehicle batteries, power electronics, cooling systems, hydrogen engines, and fuel-cell applications. Product concepts such as ElectroHold Dielectric, ElectroHold Flameproof, and ElectroHold EMC Shield target different combinations of electrical and thermal performance. The company’s research activity includes partnerships with vehicle manufacturers, Tier 1 suppliers, universities, motorsport organizations, and publicly supported UK technology programmes. It contributed coatings to Project Brunel, an Advanced Propulsion Centre collaboration focused on a hydrogen-fuelled commercial-vehicle engine. In 2024, Zircotec began leading CeraBEV, a collaboration with Cranfield University focused on ceramic coatings for battery-electric-vehicle enclosures and cooling plates. The project seeks to combine dielectric insulation and flame resistance while enabling greater use of lightweight aluminium and polymer-composite materials. Zircotec remains an active specialist technology manufacturer rather than a mass-market consumer brand. Its differentiation rests on proprietary coating know-how, high-temperature testing capability, application engineering, and the ability to adapt ceramic materials to difficult geometries and emerging powertrain requirements. Its historical automotive and motorsport reputation provides a route into OEM and industrial work, while its current development agenda is increasingly connected to electrification, hydrogen, thermal runaway mitigation, and lightweight vehicle construction.

Zircotec’s technology traces back to research conducted within the United Kingdom Atomic Energy Authority at the Atomic Energy Research Establishment near Harwell in Oxfordshire. The original work addressed high-temperature coatings and thermal barriers for nuclear-industry conditions. This heritage gave the technology an emphasis on heat resistance, durability, controlled application, and performance under severe operating environments. The first identified motorsport use occurred in 1994, when the coatings were applied to Subaru rally-car exhaust systems to reduce heat transfer into the cabin. The success of that application helped demonstrate that a technology developed for nuclear engineering could solve practical problems in racing and vehicle design. Further applications followed in Formula One, trucks, and other specialist vehicles. In 2003, the business was acquired by a venture-capital fund. Under its new ownership, it moved its commercial focus away from primarily nuclear-sector work and toward general industrial, automotive, and high-performance applications. The company developed Thermohold coatings for performance and classic vehicles, including Performance White, a dual-layer plasma-sprayed ceramic coating. In 2007, Terry Graham became managing director. The same year, Koenigsegg announced the use of Zircotec coatings on its CCX supercar, and Zircotec supplied thermal-protection technology for a steam-powered land-speed-record attempt that subsequently succeeded. Zircotec expanded its materials portfolio in 2008. It developed a ceramic coating for composite substrates and launched Performance Colours, which added a coloured finish to the Performance White formulation. The composite work was significant because it addressed a recurring engineering problem: lightweight polymer-based components can offer weight and design advantages but may be vulnerable to heat from exhausts, engines, brakes, and other powertrain parts. Ceramic protection can create additional separation between the component and a heat source without requiring a heavier metallic replacement. The company’s directors completed a management buyout in early 2009. In 2010, Zircotec moved its headquarters to Abingdon, where additional capacity was available for production and future growth. The company then broadened its offering from fixed ceramic coatings to flexible insulation. In 2011, it introduced ZircoFlex, described as the first commercially available flexible ceramic heat shield. The product used a ceramic insulating layer with metallic backing and could be formed around irregular or restricted spaces. It found potential uses in motorsport, automotive engineering, aerospace, offshore engineering, and industrial equipment. Zircotec’s automotive and engineering applications expanded through work with manufacturers, motorsport teams, and specialist suppliers. Its coatings were associated with exhaust systems, manifolds, composite diffusers, intake ducts, carbon-fibre wheels, and other heat-sensitive parts. Examples cited in connection with the company include the Aston Martin One-77 and Valkyrie, Ducati Diavel Diesel, Lamborghini Murciélago, Koenigsegg CCX, and Pagani Zonda. The company also developed relationships with racing organizations and maintained a technical partnership with Power Maxed Racing from 2018. A fire at Zircotec’s premises in July 2019 caused a temporary relocation. The company subsequently completed a larger Abingdon facility in October of that year, intended to increase production capacity and support a larger workforce. This expansion provided a platform for broader industrial and automotive development rather than limiting the business to niche motorsport work. In 2021, Zircotec announced ZircoFlex SHIELD, a higher-performance heat-shield system using multilayer construction and metallic encapsulation. The product was aimed at applications facing greater continuous thermal loads than earlier flexible products. In 2022, the company obtained another building in Abingdon for technology directed toward low- and zero-carbon vehicles. Zircotec’s later strategy has increasingly focused on electrification and alternative powertrains. Its development work includes dielectric, flame-resistant, electromagnetic-shielding, and thermal-barrier coatings for batteries, busbars, power electronics, cooling systems, hydrogen engines, and fuel cells. The company contributed ceramic coating technology to Project Brunel, an Advanced Propulsion Centre programme involving Cummins, Johnson Matthey, and PHINIA to develop a hydrogen-fuelled commercial-vehicle engine. In 2024, Zircotec began leading CeraBEV, a collaboration with Cranfield University supported through the Advanced Propulsion Centre. The project aims to develop a single-layer ceramic coating that combines electrical insulation with flame resistance for battery-electric-vehicle enclosures and cooling plates. The intended benefit is to enable lighter aluminium and polymer-composite structures while meeting thermal and electrical safety requirements. The project’s reported testing and simulation work continued through 2025, including collaboration with Cranfield University and MIRA. Today, Zircotec operates as an active specialist manufacturer and technology developer. Its business combines contract and application-specific coating work with branded products such as Performance Colours, ZircoFlex, and ZircoFlex SHIELD. The company’s historical expertise in high-temperature ceramic processing remains central, while its growth opportunities increasingly lie in thermal management, battery safety, hydrogen propulsion, lightweight materials, and other engineering challenges associated with the transition to lower-carbon vehicles.

• 2024

  CeraBEV project begins

  [1]Zircotecen.wikipedia.org

  Zircotec began leading a Cranfield University collaboration on ceramic coatings for battery-electric-vehicle applications.

• 2022

  Additional Abingdon building acquired

  [1]Zircotecen.wikipedia.org

  The company obtained a further facility dedicated to technologies for low- and zero-carbon vehicles.

• 2021

  ZircoFlex SHIELD announced

  [1]Zircotecen.wikipedia.org

  Zircotec announced a multilayer heat-shield system for higher thermal loads.

• 2019

  Premises fire and capacity expansion

  [1]Zircotecen.wikipedia.org

  A fire caused a temporary relocation, followed by completion of an expanded Abingdon facility later in the year.

• 2018

  Technical partnership with Power Maxed Racing

  [1]Zircotecen.wikipedia.org

  Zircotec began a technical partnership with Power Maxed Racing.

• 2011

  ZircoFlex introduced

  [1]Zircotecen.wikipedia.org

  The company introduced a flexible ceramic heat-shield material for confined and irregularly shaped applications.

• 2010

  Headquarters moved to Abingdon

  [1]Zircotecen.wikipedia.org

  Zircotec relocated its headquarters to Abingdon to support increased capacity and growth.

• 2009

  Management buyout completed

  [1]Zircotecen.wikipedia.org

  The company’s directors completed a management buyout.

• 2008

  Performance Colours launched

  [1]Zircotecen.wikipedia.org

  Zircotec introduced coloured finishes based on its Performance White ceramic coating.

• 2007

  Terry Graham becomes managing director

  [1]Zircotecen.wikipedia.org

  Terry Graham was appointed managing director as the company expanded its automotive and performance-vehicle activities.

• 2003

  Business acquired by a venture-capital fund

  [1]Zircotecen.wikipedia.org

  The business shifted its commercial emphasis from nuclear-sector work toward general industrial and automotive applications.

• 1994

  First reported motorsport application

  [1]Zircotecen.wikipedia.org

  Zircotec’s thermal-barrier coatings were used on Subaru rally-car exhaust systems to reduce heat entering the cabin.

A specialist, engineering-led provider of ceramic thermal-management and heat-protection technologies for demanding automotive, motorsport, industrial, aerospace, and low-carbon mobility applications.

• Ceramic thermal-barrier coating

  Primary Range

  The Primary Range is positioned as a cost-conscious ceramic coating option for components requiring moderate thermal protection. Like Zircotec’s other plasma-sprayed systems, it is applied to a prepared substrate to create a heat-resistant ceramic layer. Typical uses include automotive exhaust and engine components where reducing radiant and conductive heat is useful but the most demanding formulation is not required.

• High-performance ceramic coating

  Performance White

  Performance White is a higher-grade dual-layer ceramic thermal-barrier coating developed for demanding automotive, motorsport, and classic-car applications. It is intended to reduce heat transfer from exhausts, manifolds, and related components while providing a durable ceramic surface. The coating has also served as the technical base for Zircotec’s coloured coating range.

• Coloured ceramic thermal coating · 2008

  Performance Colours

  Performance Colours combines the thermal-barrier characteristics of Performance White with a coloured exterior finish. The range was created for visible automotive parts where appearance, cleaning, and maintenance matter alongside heat protection. It has been marketed particularly toward performance vehicles, motorsport, and classic-car applications.

• Ceramic thermal-barrier coating

  Thermohold

  Thermohold refers to Zircotec’s thermal-barrier coating technology developed for high-performance automotive and classic-car use. Plasma-sprayed ceramic layers can reduce heat transfer from hot components and help protect nearby wiring, bodywork, composites, and passenger compartments. The technology has also been adapted for specialist motorsport and composite applications.

• Flexible ceramic heat shield · 2011

  ZircoFlex

  ZircoFlex is a thin, formable ceramic heat-shield material introduced in 2011. It combines a ceramic insulating layer with metallic foil backing, allowing it to be bent, wrapped, or shaped around restricted spaces without losing its basic thermal-protection function. Single-, double-, and triple-layer configurations are used in engine compartments, transmission tunnels, underbody areas, motorsport systems, aerospace equipment, and industrial installations.

• High-temperature multilayer heat shield · 2021

  ZircoFlex SHIELD

  ZircoFlex SHIELD is a more heavily constructed heat-shield system using multiple layers and metallic encapsulation. It is designed for higher thermal loads than earlier flexible products and is intended for applications requiring compact, lightweight insulation around hot automotive, industrial, and powertrain components. The system is specified for continuous operating conditions reaching up to approximately 1000 degrees Celsius.

• Composite thermal-protection coating · 2008

  Composite-material ceramic coatings

  Zircotec develops plasma-sprayed ceramic coatings for fibre-reinforced polymers and other composite substrates. These coatings are intended to let lightweight components operate closer to exhausts, brakes, engines, and other heat sources. Reported applications include composite diffusers, intake ducts, motorsport components, and carbon-fibre wheels, where thermal protection can support weight reduction without replacing the composite with a heavier material.

• Dielectric ceramic coating

  ElectroHold Dielectric

  ElectroHold Dielectric is an electric-vehicle-oriented coating concept designed to combine electrical insulation with thermal-management capability. It is intended for potential use on battery housings, busbars, power-electronics components, and related structures made from materials such as aluminium, steel, or composites. The technology is aimed at enabling lightweight construction while meeting high-voltage insulation requirements.

• Flame-resistant ceramic coating

  ElectroHold Flameproof

  ElectroHold Flameproof is designed to resist extreme short-duration temperatures and slow the spread of heat during battery or powertrain failure events. Its intended role is to delay or limit thermal propagation in electric-vehicle battery enclosures and other high-temperature systems. The product forms part of Zircotec’s broader effort to adapt ceramic protection for electrified powertrains.

• Electromagnetic shielding coating

  ElectroHold EMC Shield

  ElectroHold EMC Shield is intended to reduce electromagnetic interference affecting sensitive electrical and electronic systems. It represents an extension of Zircotec’s ceramic-materials expertise into electrified vehicles and power electronics, where thermal protection, electrical insulation, and electromagnetic compatibility may need to be addressed together.

• 2024CeraBEV

  Electric vehicles · Battery technology · United Kingdom research and development

  Zircotec began leading the CeraBEV collaboration with Cranfield University to develop ceramic coatings combining dielectric insulation and flame resistance for battery-electric-vehicle enclosures and cooling plates.

  Outcome. The project continued into 2025, with reported testing and simulations indicating improved performance compared with existing solutions.

  Source
• 2018Power Maxed Racing technical partnership

  Motorsport · United Kingdom

  Zircotec established a technical partnership with Power Maxed Racing, supporting the use and development of thermal-management solutions in racing applications.

  Outcome. The partnership provided an ongoing motorsport test and visibility environment for Zircotec technology.

  Source
• 2007Koenigsegg CCX application

  Luxury automotive · Performance automotive

  Koenigsegg announced the use of Zircotec coatings on its CCX supercar, giving the technology visibility in the high-performance and luxury-vehicle sector.

  Outcome. The application reinforced Zircotec’s positioning as a supplier of specialist thermal-management technology for high-performance vehicles.

  Source
• 2007World land-speed steam-car record attempt

  Motorsport · Specialist engineering

  Zircotec supplied thermal-protection coatings for sensitive components in a steam-powered land-speed-record project.

  Outcome. The record attempt was successful the following year.

  Source
• 1994Subaru rally-car thermal-protection application

  Motorsport · Automotive

  Zircotec’s coatings were applied to Subaru rally-car exhaust systems to reduce heat entering the cabin. The application helped establish the company’s technology in motorsport and demonstrated its relevance outside nuclear engineering.

  Outcome. The application was reported as successful and was followed by use in other vehicles, including Formula One cars and trucks.

  Source

• 2024

  Expansion into battery-electric-vehicle thermal and electrical protectionStrategy

  Background

  Electrified vehicles require lightweight materials that can also withstand high voltage, heat, flame, and thermal-propagation events.

  Action taken

  Zircotec led the CeraBEV project with Cranfield University and developed related ElectroHold coating concepts.

  Aftermath

  The initiative positioned the company for applications in battery enclosures, cooling plates, power electronics, and other low-carbon vehicle systems.

  Source

• 2021

  Introduction of ZircoFlex SHIELDGeneration change

  Background

  Some customers required greater thermal attenuation than earlier flexible heat-shield constructions could provide.

  Action taken

  Zircotec announced a multilayer, metallic-encapsulated heat-shield system for higher thermal loads.

  Aftermath

  The product extended the ZircoFlex family toward more severe and continuous-temperature applications.

  Source

• 2011

  Launch of ZircoFlexProduct launch

  Background

  Rigid coatings and conventional heat shields can be difficult to use in confined or irregularly shaped spaces.

  Action taken

  Zircotec introduced a flexible ceramic heat-shield material that could be bent and formed around components.

  Aftermath

  The product broadened Zircotec’s addressable market into aerospace, offshore, industrial, and wider automotive applications.

  Source

• 2010

  Move to larger Abingdon headquartersStrategy

  Background

  The company required additional production capacity and space to support anticipated growth.

  Action taken

  Zircotec relocated its headquarters to Abingdon, Oxfordshire.

  Aftermath

  The move supported subsequent manufacturing expansion and remained the foundation of the company’s Abingdon operations.

  Source

• 2009

  Management buyoutM&A

  Background

  The directors pursued greater control over the company after its earlier venture-capital ownership period.

  Action taken

  Zircotec’s directors completed a management buyout.

  Aftermath

  The company continued operating as an independent specialist technology business and expanded its facilities and product range.

  Source

• 2003

  Shift from nuclear applications toward automotive and industrial marketsStrategy

  Background

  After acquisition by a venture-capital fund, Zircotec sought broader commercial applications for its high-temperature coating technology.

  Action taken

  The business redirected development and sales attention toward general industry, automotive engineering, motorsport, and performance vehicles.

  Aftermath

  The shift created the basis for products such as Thermohold, Performance White, and Performance Colours and established the company’s modern automotive identity.

  Source

• 2024

  Zircotec leads CeraBEV battery-electric-vehicle project[1]Zircotecen.wikipedia.org

  Product launch · Other

  Zircotec began leading a collaboration with Cranfield University to develop ceramic coatings combining dielectric insulation and flame resistance for battery-electric-vehicle enclosures and cooling plates.

• 2022

  Zircotec adds facility for low- and zero-carbon vehicle technology[1]Zircotecen.wikipedia.org

  Other

  The company acquired an additional building intended for technologies supporting low- and zero-carbon vehicles.

• 2021

  Zircotec announces ZircoFlex SHIELD[1]Zircotecen.wikipedia.org

  Product launch · Product generation

  Zircotec announced a multilayer heat-shield product designed to provide greater thermal attenuation for demanding applications.

• 2019

  Zircotec premises fire causes temporary relocation[1]Zircotecen.wikipedia.org

  Other

  A fire at the company’s premises led to a temporary move to a nearby facility while the business continued its operations.

• 2019

  Zircotec completes expanded Abingdon facility[1]Zircotecen.wikipedia.org

  Other

  The company completed a larger Abingdon site intended to substantially increase manufacturing capacity and accommodate workforce growth after the premises fire.

• 2010

  Zircotec relocates headquarters to Abingdon[1]Zircotecen.wikipedia.org

  Other

  The company moved its headquarters to Abingdon to increase production capacity and support expected business growth.

• 2008

  Zircotec develops ceramic coating for composite materials[1]Zircotecen.wikipedia.org

  Product launch · Other

  The company developed a plasma-sprayed ceramic coating intended to allow composite components to operate at temperatures above the normal limits of their substrate materials.

• 2008

  Zircotec launches Performance Colours[1]Zircotecen.wikipedia.org

  Product launch

  Zircotec introduced a coloured version of its Performance White ceramic coating, combining thermal protection with a more maintainable visible finish.

1. 1Zircotecen.wikipedia.org