ARMOURED STEEL FABRICATION

UK-based, Armoured Steel Fabrication Specialist

High-Hardness and Ballistic-Grade Materials

As a dependable partner for armoured steel projects in the UK where protection and quality are paramount, our team excels in welding high-hardness steels and machining ballistic-grade materials. We ensure components meet rigorous tolerance and performance standards, serving clients across defence, security, and OEM sectors.

  • Projects Managed from Drawing to Delivery
  • Expertise in Armoured and High-Hardness Steels
  • In-House Fabrication, Machining & Assembly
  • MIG, TIG & Advanced Welding for Hardened Materials
  • Heavy Fabrication up to 10 Tonne Handling
  • BS3834-2 Certified Welding for Defence Standards
  • Leak & Pressure Testing for Sealed Enclosures
  • ISO 9001:2015 Quality Control with Documentation

Call us today on 02476 370 272, or send details of your project using the contact form below.

Universal Fabrications aren’t just fabricators — they’re a critical part of our defence manufacturing capability. Their ability to work with armoured steels, especially around welding and machining, gives us total confidence in the field.

Manufacturing Armoured Steel for Defence Vehicles

Universal supports its customers through welding, machining and assembling fabrications that provide unmatched protection against bullets, shrapnel, explosions, and piercing threats while enabling mobility and agility.

Our customers benefit from fabrications with the following key characteristics:

  • Superior Ballistic Protection: Shields crews and critical components from high-velocity impacts, reducing vulnerability in combat
  • Lightweight Design for Enhanced Mobility: Advances in alloys allow for lighter vehicles that evade threats more effectively, with potential weight savings compared to traditional materials
  • Durability and Low Maintenance: Offers long-term resistance to corrosion and wear, making it cost-effective for military and law enforcement fleets
  • Versatility: Suitable for hulls, panels, and add-ons, supporting everything from armoured personnel carriers to civilian security vehicles.

With the technological advancements in lighter, tougher armoured steel alloys, our customers continue to benefit from the fact that we are an approved purchaser of armoured steels.

armoured steel fabrication part on mastiff vehicle manufactured by Universal Fabrications

Midlands-based, Armoured Steel Fabricator

Fabrication & Welding High-Hardness Steels

We produce protection panels, hull structures, and modular armour kits from various hardened steels. Welding is precisely controlled to avoid heat-affected zone (HAZ) softening, with customised procedures for ballistic-grade materials. All our welders hold BS EN ISO 9606-1 qualifications, underpinned by BS EN 3834-2 certification.

We commonly handle steels including:

  • Armox® 370T – Ideal for vehicle applications with good ballistic properties and workability, offering around 370 HBW hardness.
  • Armox® 500T – Provides exceptional toughness with 480-540 HBW hardness and minimum yield strength of 1250 MPa, perfect for ballistic panels and vehicle protection.
  • Armox® 600T – Ultra-high hardness of 570-640 HBW for add-on protection, ensuring market-leading steel protection in demanding.
  • MIL-A-46100 & MIL-A-12560+ – U.S. military-standard steels.
  • RHA (Rolled Homogeneous Armour) – Foundational armour material.
  • 500HB / 600HB – High-hardness steels for wear and blast resistance.
  • High-yield and HSLA grades – For lightweight, high-strength applications.
  • Custom-specified grades – For specialised security and OEM platforms.

We accept client-supplied materials or source them from vetted suppliers in the UK.

Controlled Heat and Repeatable Welding for Ballistic-Grade Steel

For uniform structures like turret rings or armour subframes, we utilise robotic welding to ensure consistency and minimise distortion. Certified engineers oversee all welding to preserve material hardness and structural integrity.

Precision CNC Machining for Armoured Components in the UK

Machining hardened steels demands specialised tooling, optimal speeds, and effective coolant systems. Our CNC mills and lathes deliver flat, precise surfaces and boreholes on heavy-gauge parts, whether pre-welded assemblies or individual components. Post-weld machining is available to achieve exact tolerances.

  • Up to 2m x 2m milling envelope
  • 500mm diameter turning capacity
  • Crane handling for assemblies up to 10 tonnes

Armour Chassis & Module Assembly

We oversee intricate assemblies, from complete chassis structures to bolt-on armour panels, integrating fabrication and machining. We can include accurate mounting points for drivetrains, weapons systems, and electronics.

Testing & Surface Protection for Armoured Steel Projects

For sealed armoured enclosures, we conduct pressure and leak testing. Protective coatings are applied to combat corrosion and wear, with options such as:

  • Blasting and priming
  • Mil-spec paint systems
  • Powder coating for enhanced durability

Accredited Quality Systems

All processes comply with ISO 9001:2015, offering full traceability. We supply weld maps, procedures, First Article Inspection Reports (FAIRs), and detailed inspection reports. Our inspection team employs calibrated tools, including Coordinate Measuring Machines (CMMs), to confirm dimensions and geometry.

From Field-Tested Prototypes to Production-Ready Armoured Fabrications

Whether it’s a single blast panel or ramping up production for a fleet, Universal Fabrications is ready to meet your armoured steel manufacturing requirements. We understand the mission critical nature of your projects and can offer you quality, consistency, and peace of mind from an experienced operator.

amroued steel fabrication on army challenger

FAQs: Armoured Steel Manufacturing and Fabrication

Universal is a leading armoured steel fabricator. Our BS EN 3834-2 certified team uses controlled processes to prevent HAZ softening, delivering reliable results for defence applications in the Midlands.

We are an approved armoured steel purchaser and can support the full range of requirements. We work with Armox® series (e.g., 500T with 480-540 HBW hardness), MIL standards, RHA, and custom grades for superior protection.

Universal has over 15 years of manufacturing armoured, and non-armoured spares and welded fabrications. From machined components, armoured panels to full vehicle chassis. We have supported Mastiff, Ridgback, Wolfhound, Challenger 3.0, Boxer and LC300.

We are based in Coventry, serving the Midlands and the wider UK for armoured steel projects.

Get in touch to see how we can support your production requirements. Call us today on 02476 370 272 or send details of your project using the contact form below.