University of Bath and Cross Manufacturing Limited KTP 24_25 R3

Aeroplane engines and industrial gas turbines are getting new seals that stop hot gases from leaking past rotating shafts. These seals—brush seals made of densely packed metal fibres, and film-riding seals that float on a thin gas layer—are being redesigned to handle higher temperatures and pressures while reducing friction. The project brings together engineers at the University of Bath and Cross Manufacturing Limited to develop the next generation of these components. The problem is straightforward: current seals leak more than engineers would like, wasting fuel and increasing carbon emissions. Better seals mean engines run more efficiently, burn less fuel, and produce fewer pollutants. For aircraft, that translates directly into lower operating costs and reduced environmental impact. For power generation and industrial compressors, the same principle applies. If the research succeeds, Cross Manufacturing will be able to produce seals that are both higher-performing and cheaper to manufacture, opening up new markets in sustainable propulsion—hydrogen turbines, electric-hybrid aircraft, and other emerging technologies. The work is applied engineering, not fundamental science, with a clear commercial endpoint: optimised manufacturing processes and a product ready for the global shift toward cleaner energy.