Rebuilding the UK’s Small-Arms Sector: The Vision Behind Project Grayburn
Rebuilding a nation’s small-arms sector from the ground up while simultaneously introducing advanced battlefield technology is no small task. This challenge lies at the heart of Project Grayburn, an ambitious procurement initiative that could redefine not only the British Army’s next-generation rifle but also the future of the UK’s defense industry. At the center of this effort is BDT UK, the UK subsidiary of Beretta Holding Group, which has presented a detailed plan for localizing manufacturing on British soil.
The proposal outlines four key stages of UK content in the production process:
- 5%
- 20%
- 80%
- 100%
Each stage represents a progressive step toward full domestic production. Initially, parts are manufactured in Beretta’s European facilities and then assembled, tested, and finalized in the UK using what is known as “complete knockdown” (CKD) assembly. Jack Cadman, Law Enforcement and Military Group Manager at BDT UK, explained that these percentages are not rigid benchmarks but rather strategic milestones. He emphasized that while assembly-only factories may be outdated, this first phase is essential for training a new workforce in weapons manufacturing.
As the project moves forward, the level of UK content increases. At the 20% stage, local partners would produce critical components such as upper and lower receivers and forends, with assembly and testing conducted locally. The 80% stage involves bringing most of the manufacturing onshore, except for the barrel—a component deemed vital during times of need. Finally, the 100% stage would see cold-hammer-forged barrels produced domestically, a complex process that reshapes steel under high pressure to achieve strength and precision.
The Role of the Small Arms Hub
BDT’s bid includes the development of a “Small Arms Hub” at its Skydock test centre in Lincolnshire. This site already features a 210-meter underground ballistic range, originally used for World War II aircraft weaponry testing. If selected, BDT would expand the facility with a new 2,500-square-meter production factory, creating skilled jobs locally and enabling technology transfer and skill development. The phased schedule projects initial deliveries in 2030, with the completion of the 170,000-rifle requirement by 2042.
The Technical Components
The BDT package consists of two established platforms: the Beretta NARP and the Sako M23. The NARP, chambered in 5.56×45mm NATO, resembles an AR-15 externally but features a redesigned short-stroke gas piston system, a two-position manual gas regulator for suppressed operation, and fully ambidextrous controls. Marco, international sales lead at Beretta, noted that while the rifle looks like an AR-15, its internal design is entirely new. It includes a user-replaceable barrel with lengths ranging from 11.5 to 16 inches and a modular forend with M-Lok and Picatinny mounting points for accessories.
The Sako M23, derived from the AK24 program, is fielded by Sweden and Finland and praised for its modularity, suppressor-readiness, and reliability in cold climates. Cameron from Sako highlighted the availability of multiple barrel lengths, including 11.5-inch CQB, 14.5-inch general-purpose, 16-inch infantry, and a 7.62 designated marksman rifle. Both rifles are paired with Steiner’s NATO-standard optics, such as the M8Xi 1–8× LPVO and T1Xi red dot sight, offering both long-range accuracy and quick target acquisition.
Strategic Implications
The strategic implications of BDT’s approach are significant. The UK has long struggled to balance cost-effective off-the-shelf procurement with sovereignty capabilities, a challenge exacerbated by recent global events. As outlined in recent policy analysis, the UK’s defense industrial strategy is shifting toward onshore manufacturing, long-term relationships, and potential exports. The upcoming Defence Industrial Strategy, expected in late spring 2025, will prioritize alignment with economic growth, national security, and supply chain resilience.
BDT’s phased localization approach directly supports these goals. By establishing domestic manufacturing capabilities, such as cold-hammer-forged barrel production, the UK could gain greater supply chain resilience and position itself as a global exporter of advanced small arms systems. Cadman emphasized that the goal is not just final-phase manufacturing but deeper supply chain resilience, leveraging Beretta’s experience in establishing production for the M9 pistol in the US and the ARX160 in Qatar.
Engineering Trends and Future Prospects
From an engineering perspective, the adoption of short-stroke gas piston systems in the NARP and M23 aligns with global trends in modern assault rifle design. These systems, used in rifles like the CZ Bren 2 and Steyr AUG, offer cleaner operation, enhanced reliability, and modularity—key factors for military use. The ability to easily change barrels, configure stocks, and integrate advanced optics reflects a broader trend toward adaptable, user-friendly weapon systems.
For the UK, embracing such an approach could mark a turning point. By integrating technology transfer, workforce development, and supply chain resilience into procurement, Project Grayburn offers a model for how defense buying can meet both operational needs and national industrial policy. The success of this initiative will depend not only on technical expertise but also on the government’s willingness to invest in sovereign capability before it is lost.