Electroformed barrier technology hits project milestones, use case potential
Under the LEEF project, leading edge protection layer for composite structures developed by Ultima Forma and Polar Technology is being considered for eVTOL/UAV rotor and propeller blades, aerofoils and outlet guide vanes.
Source | Ultima Forma, Polar Technology
In 2024, (Tadley, U.K.) and Polar Technology (Eynsham, U.K.) launched the Leading Edge Electro Forms (LEEF) project, collaborating to improve the ability of a composite structure to withstand erosion, impact and corrosion in extreme operating conditions. The project is now attracting interest from aerospace and defense organizations, which are seeking to explore its potential applications.
Ultima Forma have developed a leading edge protection layer through a process called electroforming, which involves electric currents depositing a thin layer of metal onto a substrate. Polar Technology is an expert in design and manufacture of critical composite products and is working closely on the best method to integrate this electroform into the structure.
All aspects of the process can be carefully controlled, with thickness and dimensions tailored depending on the application. An additional ambition of the project is to develop a U.K.-based manufacture and distribution network for leading edge protection solutions, including the manufacture of the composite structure itself, which will ultimately shorten and simplify the supply chain process.
A number of milestones have been hit since the project launched, including confirmation that the nickel-cobalt LEEF layers maintain high hardness when tested up to 900°C and beyond 1,000+ hours of ASTM B117 salt spray testing, delivering optimal performance for high-temperature platforms and mission-critical components.
Scalable parts manufacturing is underway, with the electroformed leading edges integrating seamlessly with composite aerofoils as co-molded or secondary bonded structures, enabling faster builds and retrofit flexibility.
Three key use cases have been identified as ideal demonstrators of the technology: rotor and propeller blades for eVTOL aircraft and unmanned aerial vehicle (UAV) applications, aerofoils for turbine inlets and outlet guide vanes for aircraft engines. All three cases are based on geometries provided by OEM customers in the aerospace and defense industries, which illustrates the planned routes to market. From the smallest ISR drone to the largest tactical transport, LEEFs has demonstrated delivery of lightweight, high-durability protection against rain, ice, sand and bird strikes.
“We know the market is striving for scale on a competitive level without compromising on performance or quality,” says Daniel Chilcott, business development director at Polar Technology. “This technology and collaboration has the potential to make it a reality.”
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