The manufacture of a simulant UK Advanced Gas Cooled Reactor (AGR) spent nuclear fuel (SIMFuel) was achieved by Hot Isostatic Pressing (HIP). Characterisation of HIP AGR SIMFuels, tailored to burn ups of 25 GWd/t U and 43 GWd/t U (after 100 years cooling) demonstrated fission product partitioning, phase assemblage, microstructure and porosity in good agreement with spent nuclear fuels and SIMFuels, and AGR fuels in particular. A pivotal advantage of the application of the HIP manufacturing method is the retention of volatile fission products within the resultant SIMFuel as the result of using a hermetically-sealed container. This new approach to SIMFuel manufacture should enable the production of more accurate spent nuclear fuel surrogates to support research on spent fuel management, recycle, and disposal, and the thermal treatment of fuel residues and debris.