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Formula 1 and Hypercar manufacturer in Gloucester develops tougher and more eco-friendly parts

Formula 1 and Hypercar manufacturer in Gloucester develops tougher and more eco-friendly parts

Permali, now part of the Diamorph Group, is a long-established supplier of advanced material solutions for the motorsport industry, most notably Formula 1 and World Endurance Championship (WEC) Hypercars. The company uses its extensive manufacturing capabilities to ensure that parts are precision machined to meet some of the most stringent regulatory standards in the automotive industry set by the FIA. With cars reaching top speeds of over 200+ mph and 0-60 in sub 3 seconds, it is crucial that materials conform to strict quality and safety standards whilst providing optimum performance for race teams.

Above: Toyota Racing Hypercar, World Endurance Championship Testing
15th to 18th December 2020, Portugal [credit: Toyota]


With Permali seeing tougher technical demands, the company has been focusing efforts on using its comprehensive R&D facilities to develop new product innovations for motorsport teams. Most notably this includes ‘greener composites’ which have been developed more sustainably using fibers which are sourced from recycled materials. In addition, the company has also developed an alternative greener composite which utilises natural fibers. With continuing pressure for motorsport teams to reduce their environmental impact, the business continues to pursue more eco-friendly innovations.


Above: A Mercedes Formula 1 Car, March 2022, Saudi Arabia [credit: Shutterstock]


In addition to greener materials, the business has used R&D efforts to develop more durable composite materials which see higher wear resistance on the track. The new product is actively used in Formula 1 races and was developed through the utilisation of a new fiber system which has resulted in a stronger material. Actively involved in motorsport product development, Permali’s composites engineer, Adam Pickard, commented:

“Permali has been supplying precision manufactured high-performance materials to a range of motorsport racing teams for several decades. The company has utilised its extensive R&D and manufacturing capabilities to develop unrivalled products which combine durability and lightweighting for extremely demanding motorsport environments. Developing new products to better meet environmental objectives is an exciting and ongoing project for the business and we will continue to focus on product innovation.”

Over 20 years ago the company developed its first synthetic composite design to replace densified wood. In 1998 the first Formula 1 team adopted Permali’s composite components seeing superior performance attributes such as durability and wear resistance. By 2005 all Formula 1 teams moved away from densified wood entirely in favour of Permali’s composite materials which continue to be developed.

Above: McLaren Mercedes Formula 1 Car driven by David Coulthard, Barcelona,1998. [credit: Fav Cars]


As Permali sees continued growth across automotive, defence, rail, aerospace and medical market sectors, the business has recently announced over £6 million investment from its parent company, Diamorph Group, at its Gloucester site. This is followed by a substantial recruitment drive of over 70+ roles including Manufacturing Operatives, Lab Technicians, Quality Inspectors, Warehouse and Logistics Supervisors and more.

To see Permali’s latest vacancies you can head to:

About Permali
Since 1937 Permali has been a sector leader in the manufacture, design, and qualification of composite and PU material solutions for defence, aerospace, medical, rail, automotive, and many other engineering sectors that require compliance with complex regulatory frameworks. Permali was recently acquired by Diamorph Group, a materials science-based company which has offices in several countries and operates in markets ranging from Marine through to Renewable Energy. Operating from a 10,500msq site in Gloucester, UK, Permali makes a vast range of bespoke FRP composite panels, components, and systems, based on a wide variety of resins, fibres, cores, and adhesives. Permali’s product range is extended further with the inclusion of its Tuftane® products, a range of aromatic thermoplastic polyurethane (TPU) elastic films.

About Diamorph
Diamorph is a passionate materials science-based company, boasting 3 state of the art manufacturing sites and a multitude of sales offices across the globe. The company has deep materials science knowledge in a range of technologies, to make innovative products that provide protection in a wide range of safety critical or high cost of failure activities. The business is split into 3 units:
1. Composite and Polymer Materials: products provide protection from wear, impact and electrical shock.
2. High Temperature Solutions: materials protect process integrity at temperatures between 350 and 1200 degrees C in high temperature process industries.
3. Passive Fire Protection: products designed to protect lives and buildings by stopping the spread of fire, allowing time for occupants to leave the building.

Written by Scott Cawkell – press enquiries to

Permali’s Tuftane® is used to grow human tendon tissue

A team of researchers from the University of Oxford and Devanthro GmbH have modified a robot shoulder to serve as a stretching mechanism in an effort to grow useful human tendon tissue. Permali, a manufacturer specialising in both TPU (thermoplastic polyurethane) and composite materials, donated Tuftane® TPU to the University of Oxford used in the tubular membranes, working closely with Pierre-Alexis Mouthuy, Associate Professor at the university.

Above: Humanoid bioreactor platform developed to provide engineered tendons with human-like mechanical stimulation. Credit: Fisher Studios / MedicalXPress


Over the past few decades, medical scientists have been investigating the possibility of using fibroblast cells to grow human tissue that can replace tissue lost or damaged in human patients. To that end, researchers have grown organs, skin, cartilage, and even a windpipe. But such endeavors are still in their infancy.

One area of research that has proven to be particularly challenging is growing tendon tissue. Previously engineered tissues have lacked the elasticity required for use in a human patient. Attempts have been made to increase elasticity by building devices that stretch and bend the tissue as it grows. Unfortunately, these attempts have not produced tissue that can bend, twist and stretch to the degree real tissue can. In this new effort, the researchers have taken a new approach. Instead of cultivating tendon tissue in boxes with devices that pull on it, the researchers grew it in a more human-like way—on a fabricated joint made to mimic a human shoulder.

Above: Close up of the soft transparent chamber hosting a cell-material construct. During mechanical stimulation, it is positioned at the supraspinatus tendon location on a musculoskeletal robotic shoulder. Credit: Fisher Studios / MedicalXPress


The researchers began their effort by modifying an open-source robot developed by engineers at Devanthro to allow for the addition of a bioreactor and a means to attach the new tissue as it grew. Once the bioreactor and hair-like filaments were in place on the robot shoulder, the team flooded pertinent areas with nutrients to stimulate growth. The cells were then allowed to grow over a two-week period, during which the shoulder was activated for 30 minutes each day, bending, pulling and twisting in human-like ways. At the end of the growing period, the researchers studied the resulting tissue and found that it was different from tissue grown in a static environment—but they still do not know if the tissue is an improvement on other methods. More work is required to determine if the newly grown tissue might be a close enough match to the real thing for use in human patients.

You can download the full study here.

Permali, part of the Diamorph Group, manufactures a wide variety of Tuftane® branded thermoplastic polyurethane (TPU) elastomeric films which are used in applications needing a tough, highly elastic flexible film as part of the product design.

Tuftane® films are specified in many markets, applications and environments: from artificial heart components, blood plasma bags and isolation tents in hospitals, to construction pipelining, aircraft furnishings, automotive parts and industrial valves. Tuftane® films come in a choice of over 30 grades, supplied in rolls up to 1.6 m wide, slit to width.

Gloucester based manufacturer invests in state-of-the-art fabrication site – roles available for immediate start!

Diamorph group, Permali’s new owners, has announced an exciting investment of £6m+ to support manufacturing of composite materials and bearings at its Gloucester facility. With this comes a significant recruitment drive.

Above: Snapshot of Permali’s factory


Diamorph is a passionate materials science-based company, boasting 3 state of the art manufacturing sites and a multitude of sales offices across the globe. The company have deep materials science knowledge in their chosen technologies, to make innovative products that provide protection in a wide range of safety critical or high cost of failure activities. The business is split into 3 Business Units:

  • Composite and Polymer Materials: products provide protection from wear, impact and electrical shock
  • High Temperature Solutions: materials protect process integrity at temperatures between 350 and 1200 degrees C in high temperature process industries
  • Passive Fire Protection: products designed to protect lives and buildings by stopping the spread of fire, allowing time for occupants to leave the building

The primary Composite and Polymer Materials (CPM) manufacturing site is in Gloucester; the home of Permali and the future home of Tenmat composites & Railko, some of the best-known material brands in exciting industries such as F1, Defence, Marine, Aerospace and Rail. So far, Diamorph plans to invest 6 million on developing a state-of-the-art fabrication centre and offices in the heart of Gloucester. With increased demand in these sectors, Diamorph Gloucester currently have over 70 roles available from Manufacturing Operatives, Lab Technicians, Quality Inspectors, CNC Managers to Warehouse and Logistics Supervisors.

Above: Permali has extensive experience in the motorsport market


Tony Beswick, Managing Director of the CPM business commented:

“Diamorph works on some really demanding projects, for example Permali has the prestigious honour of supplying composite parts to all Formula 1 teams on the grid as well as applications on passenger airliners – you’ve probably sat on a plane with our products on! Diamorph invests in its people and with so many exciting opportunities coming up we hope to involve the whole community in its growth and successes”

Diamorph serve customers by combining deep market knowledge with a unique capability to invent, modify and adapt the materials which make our products perform. Every day, at every level of the organisation, Diamorph works to improve the performance of our products, leveraging materials science knowledge to create improved protection for people, processes and physical assets across the globe.

For current positions please see or send your CV to


Permali BattleJacket® self-sealing fuel tank protection coating saves lives and the environment


Permali is a long established UK MoD (Ministry of Defence) approved supplier of advanced material solutions for protecting British Armed Forces, NATO and UN land, air and sea military personnel. The company’s extensive product offering of advanced composites and Tufshield® polyurethane based surface coatings, also includes (under licence) the production of BattleJacket® self-sealing elastomeric coating system. Being self-sealing, if penetrated, BattleJacket helps to protect military vehicle fuel tanks and tankers from catastrophic fires and explosions occurring. As well as protecting combat personnel, it avoids vehicles under attack becoming immobilised in the operational theatre due to fuel leakage from a ruptured tank.

BattleJacket is a patented, advanced polymer coating technology that immediately closes up and literally ‘heals’ itself when pierced by a bullet or high velocity projectile, such as shrapnel from an IED (improvised explosive device) or land mine. The multi-layered elastomeric system is designed to allow projectiles to pass through the polyurethane coating into the fuel tank, and then instantaneously reseals. The thickness of coating can be tailored to meet specific ballistic threat levels.

Image 1: BattleJacket® was developed to provide added protection to fuel tanks from high velocity projectile damage and fuel ignition fires for both armoured combat and logistical support military vehicles.


The BattleJacket coating is compatible with CARC (Chemical Agent Resistant Coating) two-component polyurethane paint, better known as camouflage paint. This unique, triple layered specialist outer protective coating system is spray applied to safety critical metal, plastic and composite parts, such as fuel tanks and fuel lines in helicopters.

BattleJacket was developed by High Impact Technology LLC (HIT) for the US Army to provide added protection from high velocity projectile damage and fire for both armoured combat and logistical support military vehicles, including land and aircraft refuelling tankers. It is a battle proven protective coating technology with nearly 20 years of service in US Army and other military applications around the world.

Image 2: The environmental and ballistic Radnor Range trials, conducted by Permali on MoD specification BattleJacket® coated metal and polymer fuel tanks, demonstrated the small arms bullet impact protection and explosive resistance capabilities to a hand grenade detonated 300mm below the coated tank.


In addition to being self-healing, BattleJacket can withstand up to 150 psi (10 bar) pressure and provides enhanced impact, abrasion, corrosion and environmental resistance against extremes of temperature (-50°C to 150°C) and UV weathering. Applications for HIT’s unique urethane polymer coating system now extend beyond the Defence sector, protecting civil structures and products such as fuel cells, holding tanks, pipelines, and railcars.


Rigorous performance evaluation   

Before entering into the licencing partnership with HIT, Permali conducted rigorous environmental testing, along with both small arms ballistic and hand grenade explosion resistance trials to assess and approve the performance of HIT’s BattleJacket coating technology. The performance evaluation was conducted over five days at Radnor Range in Shropshire; Radnor is a UK MoD accredited independent test house for the evaluation of weapons, ordnance, munitions and explosives. All the Radnor Range testing trials were witnessed by representatives from Permali, HIT and the UK Defence Science and Technology Laboratory (Dstl) executive agency, which is sponsored by the MoD.

The environmental and ballistic testing was carried on MoD specification metal and polymer heavy goods vehicle ‘saddle’ fuel tanks. Ahead of the trials, two of each type of test fuel tank were manufactured by Permali and then shipped to HIT to be triple layer coated with BattleJacket. To determine the system’s environmental performance, prior to carrying out ballistic and explosive trials, the fuel tanks were first conditioned by being subjecting to temperature extremes from -15°C to ambient and then +70°C.

Image 3: An example of the vulnerability of fuel tanks on a British army vehicle


The ballistic and explosive trials conducted tested the small arms performance of BattleJacket against various types of ballistic and fragment threat impacts, and its explosive resistance to a hand grenade detonated only 300mm below the coated tank. BattleJacket repair patches were also tested to evaluate their capability to stem fuel leakage from an exit hole, which provided a near instantaneous seal.

Dr Pete Webb, Director of Research and Development for Permali, who developed the tests, commented: “Under all environmental conditions, the Battlejacket coating performed extremely well during the ballistic and blast assessment. The coating demonstrated good multi-hit capabilities and provided a near instantaneous damp seal, with dry seals being formed typically within four minutes. For the hand grenade explosive trials, no leaks were observed post detonation, with both the plastic and metal fuel tank remaining fully functional.


Pollution prevention

An added benefit of having military vehicles additionally protected by the Battlejacket coating , particularly fuel tankers, is that it can help the environment by preventing unwanted gasoline or diesel fuel soil and water contamination from leaks or major spillages after a catastrophic incident. According to HIT technical data, BattleJacket is Title 40 Section 112 (Oil Pollution Prevention) compliant, which is a specification requirement for onshore petroleum oil handling and storage facilities to prevent contamination discharges of oil from non-transportation-related onshore and offshore facilities.

Download the BattleJacket brochure here

Bespoke Product Offering

Permali designs, manufactures and supplies a vast range of bespoke FRP composite panels, components and systems for a wide range of safety critical military and civil land, sea and air applications. The Permali product range also includes standard and bespoke Tuftane® aromatic thermoplastic polyurethane (TPU) elastic films.  To find out more visit

[BattleJacket® is a registered trademark of High Impact Technology, LLC, Oregon USA.  Tufshield® and Tuftane® are registered trademark of Permali Gloucester Ltd, part of The Diamorph Group] 

Permali Driving Cost-Effectiveness and Sustainability in Defence

In today’s ever-evolving geopolitical landscape, the demand for safety and defence measures in combat and civilian spaces is at an all-time high. However, the emergence of newer opportunities in the defence space gave rise to more stringent regulations, which started hindering defence contractors from meeting their delivery deadlines for manufacturing equipment. At the same time, to drive the movement toward greener operations, vendors in the industry are also facing issues with designing products that can be manufactured using eco-friendly materials, are lighter, and produce a lower carbon footprint. Addressing these needs with its ability to offer end-to-end manufacturing capabilities alongside a range of unique, lightweight, and robust composite solutions is England-based Permali.

Above: Permali’s Spray Paint Coating Booth


The company’s comprehensive portfolio is backed by its in-house experts from the realms of design, material science, product development, and others, which ensures that all of a client’s needs are always met. And as a way to bridge the gap between the defence market and rising environmental laws, Permali provides a suite of composite materials that comply with the flammability, smoke, and toxic fumes emission regulations. “From design to final product delivery, we are always ready to deliver on the specifications of a client with our comprehensive in-house processing capabilities and team expertise,” says Fraser Rankin, Sales & Marketing Director at Permali. Founded in 1937, Permali was initially a contractor in the high voltage and tooling industry, providing phenolic resin-based high-pressure lamination and coating services. This work with phenolic solutions-built expertise for Permali that it leveraged to penetrate the aerospace market where phenolic resin-based components were being designed and developed for a growing number of applications and are today a mainstay.

Above: The Ajax armoured fighting vehicle which Permali is actively involved with


Over the decades, the company expanded from covering core defence sectors to several commercial and civil market sectors, offering composite solutions and eventually branching into TPU solutions. Today, Permali is a world leader in manufacturing composite materials and bespoke solutions for aerospace, defence, rail, marine, and healthcare arenas. And at the heart of this success is the company’s 10,500 sq. m. factory that boasts next-gen pressing, moulding, assemble, CNC machining facilities and dedicated wings for CAD design, inspection, and R&D. From a portfolio standpoint, Permali manufactures Permaglass composite materials in the form of laminated sheets, mouldings, and sandwich panels. In terms of processing prowess, the company prides itself in its impregnation capabilities, which has allowed it to produce products for a wide range of applications in multiple markets. “We have invested significant capital in modernizing our impregnation wing to help expand our ability to manufacture better, lighter, and more affordable products,” adds Rankin. Apart from this, Permali’s single-site processing capabilities include mechanical and flammability testing, CAD/CAM design and manufacturing, rapid prototyping (3D printing), resin mixing, high pressure pressing/moulding, 5-axis precision machining, mechanical and bonding assembly sections, all backed by an AS9100 Rev D quality accreditation.

Above: Permali has both 3 and 5-axis CNC Routers and Water Jet Cutters


On the other hand, Permali speciality prepreg fibre reinforcements, thermoplastics, ceramic plates and coating materials used by Permali for manufacturing integrated Permaglass® composite appliqué amour systems. These protection offerings comprise ballistic-grade UHMWPE fibres, including DSM Dyneema® and Honeywell Spectra Shield®, Kevlar® and Twaron® rubber-coated aramid fibres, woven and non-woven S2, E-glass fibre fabrics and tissues, alumina, silicon and boron carbide ballistic grade ceramic plates, and chemical resistant Tufshield® elastomeric PU coating Further discussing the core competencies of his company, Fraser elaborates, “Our mission is to help the defence and aerospace sectors produce lighter and cost-effective products with high longevity.” In pursuit of this, Permali approaches every client engagement with a goal to deliver as lightweight and low-cost a solution as possible. But, the company is flexible in this when it comes to higher threat level component production. For instance, in a project for the development of a helicopter component, Permali will prioritize weight and develop an end-part that showcases the highest strength. Another key facet of Permali’s flexible engagement approach is the ability to offer fair pricing as the company typically offers multiple prototypes with varying weights to choose from: lower the weight, higher the cost, and vice-versa.

Above: Type 45 Destroyer featuring Permali’s safety net systems


With such unmatched capabilities, Permali has ignited several success stories since its inception. A prime example of the company’s proven track record would be the role it played in developing the aircraft cockpit door protection upgrade in the wake of the 9/11 tragedy. Being an industry giant, Permali had anticipated such a requirement as a result of an incident in December 2000 when a passenger stormed the cockpit of BA Flight 2069 from Gatwick to Nairobi and forced the aircraft into a dive before the crew was able to overcome the intruder and regain control of the aircraft. After September 2001, Permali immediately began working with aircraft manufacturers and airlines on solutions for preventing cockpit intrusion. Subsequently, the company developed a material, branded Permaglass XFS2, which is a lightweight composite armour solution capable of stopping handgun threats, whilst also meeting all aircraft interior flammability standards, including vertical burn, heat release, and smoke & toxic fume emissions.

Above: Permali’s cargo liner and cockpit door armour features on the Boeing 737


The first airline to respond was Virgin Atlantic Airways who contracted Permali to supply retrofit cockpit door reinforcement for their aircraft in advance of the new regulations being published. This retrofit solution was supplied in October 2001, less than six weeks after the September 11 attacks took place. The company went on to work closely with Airbus and various aircraft interior manufacturers to supply solutions for Airbus, Boeing, McDonnell Douglas, Embraer and other aircraft, helping to protect thousands of aircraft and millions of passengers worldwide. Looking ahead, Permali plans to leverage its acquisition by market-leader Diamorph to expand its footprint in the U.S. and Eastern Europe as well as boost innovations in the development of materials capable of delivering cost reduction and sustainability.

Find out more about our Defence and Aerospace solutions.

To get in touch, email

New Permali composite flight deck safety systems meet the latest UK MoD fire retardancy standards for Royal Navy vessels.

New Permali composite flight deck safety systems meet the latest UK MoD fire retardancy standards for Royal Navy vessels.

Permali is the global market leader in the design and manufacture of high strength, glass fibre reinforced (GRP) composite stanchions, guardrails, deck safety net frames and ladder systems for naval warships and support vessels. UK MoD fire retardancy (FR) standards have become even more stringent since the first Permali composite stanchions were fitted on the decks of Royal Navy ships more than 30 years ago.

To meet the latest UK MoD regulatory standard to improve naval crew fire protection, Permali’s R & D team has developed Permaglass® XGR2/4, a new specialist FR composite material grade, which provides the next generation naval safety fire performance. Extensive mechanical and fire, smoke and toxicity (FST) testing to the new Defence Standard 07-247 has been carried out to validate the new material’s suitability for the demanding deck safety applications.

Figure 1: Close up shot of fabricated finished painted GRP composite stanchions


New MoD FST Def standard

Defence Standard 07-247 is the latest, more stringent MoD fire, smoke and toxicity (FST) performance standard for naval vessels. Permaglass XGR2/4 achieved the highest overall Category A1 rating possible for this enhanced FST Def standard; critically XGR2/4 fire test coupons achieved Class 1 for surface spread of flames (to BS 467 Part 6) and a fire propagation index (I) of 7.8 (to BS 467 Part 7).

Equally impressive is that Permali’s innovative new Permaglass XGR2/4 resin grade and laminate system achieves this higher FST rating while still easily meeting the demanding mechanical performance requirements of the MoD standard. Permali has been able to do this by combining its proprietary high performance, low VOC thermoset FR resin formulation with woven glass reinforcements. Typical mechanical properties listed by Permali in the published technical data sheet for Permaglass XGR2/4 include a flexural strength of 720 MPa (to BS EN ISO178) and a tensile strength of 600 MPa (to BS 2782 Part 10:Method 1003). [Figure 6. Permaglass XGR2/4 typical mechanical properties table.]

Figure 2: Permali’s safety nets on the runway of HMS Queen Elizabeth, one of two British aircraft carriers


Steve Benn, Permali Technical Manager for composites commented: “The challenge was to achieve the fire performance required by this more demanding MoD FST standard without introducing the mechanical performance loss typically associated with the addition of fire retardant fillers. Working with our customers and the MoD regulatory team, we have managed to develop a technical solution which provides the right balance of properties needed for this next generation of naval stanchions. Permaglass XGR2/4 is now specified for manufacturing all four types of safety systems that Permali supplies for naval vessels”.


Proven naval deck safety systems

The Royal Navy (RN) and other navies around the world specify Permali’s lightweight, high performance GRP products to protect crew personnel and equipment on weather decks, flight decks, and walkways. All deck safety systems developed for Royal Naval vessels are MoD approved and rigorously tested to ensure that they meet specified DNV and Lloyds register regulatory standards.

Figure 3: Permali’s stanchions feature on HMS Arygll, a Type 23 frigate


Current naval vessels in service fitted with Permali supplied deck safety systems include: Visby class corvettes; RN Type 45 destroyers and Type 23 frigates; RFA Bay class support ships; the Queen Elizabeth-class aircraft carriers, famed for being the biggest, most advanced warships ever built for the Royal Navy. In addition to naval ships, the specialist polar exploration vessel the RRS Sir David Attenborough is also fitted with Permali deck safety systems to protect personnel while on the flight deck.

Figure 4: RRS Sir David Attenborough features Permali’s safety net system on it’s flight deck


GRP stanchion benefits

The use of a GRP composite material for stanchions, guardrails and net frames provide key in-service benefits over metallic alternatives, being lightweight, vibration free, corrosion resistant, low maintenance and non-conductive. For warships, a major operational benefit of using Permali’s composite stanchions for both deck safety nets frames and guardrail stanchions is that being non-metallic they produce a significantly reduced radar detection signature.

Figure 5: Permali’s safety net system features on HMS Daring, the first Type 45


Design flexibility

Permali offers a complete range of durable deck or hull mounted modular GRP composite stanchion designs to provide rigid guardrails, PARAFIL® synthetic rope guardrails and safety nets, or removable chains. Four standard stanchion styles are manufactured to accommodate the different types of vessels and deck area safety requirements:

  • Type A stanchions (for fixed position guardrails)
  • Type B stanchions (can fold fore and aft of the deck)
  • Type D stanchions (fold onto the deck)
  • Quick Release/Removable stanchions (for access areas)

Stanchion systems are supplied by Permali ‘ready to install’, complete with all the stainless steel deck base fixings, positive lock fittings and lug bolts specified for guardrail and net system designs. All fabricated composite stanchions, rigid guardrails, ‘quick release’ lift off gates and deck safety net frames are finish painted in-house with a two part paint system to the required vessel colours. Lift off gates are installed to provide easy access to specific deck areas for ‘over the side’ Replenishment at Sea (RAS) and to enable unobstructed helicopter maintenance.

Figure 6: Typical Properties Table – Extract from Permali Permaglass XGR2/4 technical data sheet


Bespoke designs and modifications are incorporated by Permali to suit the type of vessel and customised requirements such as: rail height and width, numbers of handrails, seated angle and type of hinge points; manual or automated operation. For aircraft carriers, approach lighting is included in flight deck net safety systems.

Permali designs, manufactures and supplies a vast range of bespoke FRP composite panels, components, and systems, based on a wide variety of resins, fibres, cores, and adhesives for a wide range of safety critical military and civil land, sea and air applications. The Permali product range also includes standard and bespoke Tuftane® aromatic thermoplastic polyurethane (TPU) elastic films.

To find out more head to our Naval Defence page

 To get in touch email

Acquisition of Permali by Diamorph Group Holdings Ltd

Diamorph Group Holdings Limited (“Diamorph”) announces:

That it has signed a conditional agreement to acquire Permali Gloucester Limited (“Permali”), a Gloucester-based manufacturer of composites, predominately for the Defence sector. Diamorph is anticipating completion of the Permali acquisition within the coming months.

That it also completed the acquisition of Tufnol Composites Ltd (“Tufnol”), a Birmingham-based manufacturer of composites, predominately for the Aerospace industry on 5th March 2021.

Diamorph Chief Executive, Gordon MacLeman said:

“These acquisitions allow Diamorph to broaden its composites competency and enter new markets. Permali has a long history of developing bespoke composite solutions for critical Defence applications since the 1930’s, whilst Tufnol has been manufacturing high performance composites since the 1920’s and has a highly regarded brand and reputation for delivering market leading wear performance in the Aerospace sector.”

Above: Diamorph Group HQ, Tenmat Trafford Park, Manchester, UK


Above: Permali Factory, Gloucester, UK

Permali Invests Half a Million Pounds in 3D CNC Router and Waterjet Cutter

As part of the company’s long term business growth strategy, Permali has added a new CMS tecnocut idroline S2040 5-axis waterjet cutter and CMS MX5 gantry 5-axis CNC machining centre to its manufacturing facilities in Gloucester, UK. This major capital investment has expanded Permali’s production capacity and upgraded its in-house 3D machining capabilities to machine large, more complex components from composites, metals, ceramics and other high performance engineering materials.

Targeting new business 

Permali’s new 5-axis CNC Router


The new CMS waterjet cutter has a 4650mm x 2050mm bed size, designed to ensure very high standards of cutting accuracy. To increase operator safety and reduce over-spill, this latest model has automatic sliding glass barriers. The technocut idroline S2040’s innovative 5-axis cutting head features CMS jet drive compensation (JDC) technology which minimises conicity, providing high quality finish and size tolerance 3D machining capabilities. The proprietary JDC cutting head features include: infinite rotation for nesting cuts without breakpoints; cutting from 0° to 62°; automatic taper compensation up to 60° tilt angle; 3D machining; profile countersinking and chamfering; monitoring of cutting component wear.

The new CMS MX5 gantry 5-axis machining centre has a large 4000mm x 3200mm x 700mm work envelope, designed with a highly stable monobloc unit structure and fitted with CMS’s latest generation motors, drive systems and moving part technology. The MX5 provides Permali with productivity performance, precision and reliability, even when machining the most challenging engineering materials.

The addition of the new 5 axis waterjet cutter and CNC machining centre is enabling Permali to target new business in both defence and civil markets. Fraser Rankin, Director of Sales & Marketing for Permali explains: “Our 3-axis and new 5-axis water jet cutters and CNC milling and routing machines are now being used to develop new applications, particularly for more complex composite parts, not only for our long established air, sea and land defence customers, but also increasingly for non-military market sectors, such as medical, motorsport, civil aerospace, rail and automotive.”   

Permali’s new 5-axis Water Jet Cutter


Fraser went on to say: “An example of this is Permali’s new development of complex shaped vacuum infused FRP mouldings for use on London Underground rolling stock, compliant with EN45545 fire safety standards.  The parts in question take full advantage of the enhanced vertical integration capabilities that Permali used in-house on this project. These included 3D scanning, reverse engineering, CAD/CAM manufacturing, vacuum infusion, 5-axis machining, and painting.”

Permali designs, manufactures and supplies a vast range of bespoke FRP composite panels, components, and systems, based on a wide variety of resins, fibres, cores, and adhesives. The Permali product range also includes standard and bespoke Tuftane® aromatic thermoplastic polyurethane (TPU) elastic films.

To find out more email

Permali developing new breakthrough composite structures for Hydrogen Powered Buses

Permali developing new breakthrough composite structures for Hydrogen Powered Buses

Permali has won UK Government funding to develop a lightweight composite solution that will allow existing diesel-powered buses to be retrofitted with zero-emission hydrogen powertrains. The objective is to rapidly develop an affordable green technology alternative that can accelerate the ability for the UK to meet its net zero emissions target.

The funding has been awarded by the Office for Low Emission Vehicles (OLEV) through the Niche Vehicle Network (NVN). The Permali R & D team, located at the company’s main site in Gloucester, will be working on this development project in collaboration with leading hydrogen and fuel cell specialist company Arcola Energy and the UK National Composites Centre (NCC). The partnership project is initially aimed at buses, but the new technology concept should be transferable to a wider range of vehicles, such as heavy-duty goods vehicles, trains and even aircraft.

Above: The Metrodecker H2 incorporates a hydrogen fuel cell powerpack developed by Arcola Energy. It can carry more than 90 passengers with a range of between 200 and 250 miles depending on specification and route.


Collaborative Project Objectives

Permali will work in close collaboration with the NCC to design and manufacture the proof of concept system. Arcola Energy will integrate and test the system with the hydrogen cylinders to achieve regulatory compliance and fit the new system to a double decker bus. The NCC approached Permali knowing their extensive experience in handling complex projects and proven track record in the F1 automotive, aerospace, defence, rail and energy sectors as a highly responsive provider of advanced materials solutions.

The project focus for Permali will be on the development and production of a low-cost, lightweight composite system which will structurally support the hydrogen fuel cylinders. The target for the Permali development team is to halve the weight of the current metallic hydrogen fuel tank structure and to increase energy storage by 25%, while still providing the required structural performance to meet the vehicle road safety standards.

Permali’s Sales & Marketing Director, Fraser Rankin, commented: “This is a fantastic win for Permali demonstrating the ability to create an innovative solution within a short time frame and to the complexity of the project requirements. Our dedicated and loyal team have been instrumental in the funding win and I’m excited to see Permali’s influence on a breakthrough project which contributes towards the UK’s carbon neutral goal.”

Benefits of Hydrogen Power

Hydrogen fuel provides a highly efficient zero-emission alternative to diesel. It is especially suited for buses which operate on long-distance, high-capacity routes. By retrofitting existing diesel engine buses with hydrogen powertrains, bus operators will be able to cost effectively run zero emission fleets, with a combination of retrofitted hydrogen powered buses for longer routes alongside electric battery powered buses for shorter routes.

For more information please contact

Permali installs Flight Deck Safety Nets on RRS Sir David Attenborough

Permali installs Flight Deck Safety Nets on RRS Sir David Attenborough

The UK’s most advanced polar research ship – RRS Sir David Attenborough – left Cammell Laird shipyard for two weeks of technical sea trials.  The shipyard will formally hand over the ship to the Natural Environment Research Council (NERC).

The research ship, developed over 4 years costing £200m, will play a pivotal role in supporting UK scientists in the Artic and Antarctic. Its missions are critical for understanding and making sense of our changing climate.

Above: RRS Sir David Attenborough on the river Mersey, Liverpool


Permali’s involvement, working with Cammell Laird Shiprepairers & Shipbuilders Limited, proved to be an exciting project for the team, who showed adaptability and technical expertise to ensure the safety of the ship’s crew.

Above: Permali observes installation of it’s Flight Deck Safety Nets

The RRS Sir David Attenborough sailed across the Mersey to the Liverpool cruise terminal at high tide for crew familiarisation, where it will spend 14 days undergoing technical trials off the coast of North Wales. The shipyard engineers and BAS mariners will put the ship through its paces, performing operational checks on the propulsion, steering, engineering and navigation systems.

When technical tests are complete, the BAS ship crew will take over and spend 50 days intensive training at Holyhead Port before embarking on operational and scientific equipment trials around the Irish Sea.  The team will test anchoring, manoeuvring, dynamic positioning, and helideck landing – the safety of crew ensured by Permali’s Flight Deck Safety Nets.  Early next year the ship will undertake ice trials in the Arctic, and in November 2021 make its maiden voyage to Antarctica.

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