Heritage manufacturer integrates digital design and production technologies under the Made Smarter programme to improve efficiency and scale output while maintaining traditional craft processes

Darwen Terracotta - LtoR Siddique Rasul, Digital Project Manager, and Steve Allen, Director

Architectural ceramics manufacturer Darwen Terracotta is using digital manufacturing tools to modernise production processes as part of a wider shift among heritage craft businesses supported by the Made Smarter North West programme.

The Blackburn-based company, which produces terracotta and faience for architectural restoration and new-build projects, has introduced technologies including 3D scanning, digital sculpting, additive manufacturing and robotics alongside traditional ceramic production methods.

The adoption of digital tools has been supported through Made Smarter since 2018, providing access to digital strategy support, skills training, consultancy and an internship programme focused on manufacturing technology integration.

According to the company, the combination of craft-based production and digital workflows has enabled it to increase operational capacity, with turnover rising to £6.7 million and headcount increasing from 43 to 51 over the period of engagement.

Digital processes are being used to support design development and production efficiency, particularly in the creation and reproduction of complex architectural ceramic forms used in both restoration work and contemporary façades.

The programme forms part of a wider regional initiative encouraging traditional manufacturers to adopt digital systems to improve productivity, reduce material waste and respond to increasing project complexity and delivery constraints.

Made Smarter North West works with manufacturers across sectors including ceramics, textiles, glass and metalwork, supporting the introduction of technologies such as automated fabrication systems, digital modelling and production data tools.

Programme director Donna Edwards said the aim is to support the continuation of traditional craft industries by integrating digital capability into existing production methods rather than replacing skilled manual processes.

She added that the approach is intended to help manufacturers maintain specialist knowledge while improving competitiveness and enabling longer-term skills transfer within the sector.

Since its launch in 2019, Made Smarter North West has supported more than 2,500 manufacturers across the region through technology adoption planning, training programmes and digital transformation support.

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