Ultima Forma and Polar Technology are making major strides in the aerospace and defence sectors through their collaborative project, LEEF (Leading Edge Electro Forms) – a cutting-edge solution aimed at protecting composite components from erosion, impact, and corrosion in extreme environments.
Originally announced in mid-2024, the LEEF project combines Ultima Forma’s pioneering electroforming technology with Polar Technology’s advanced composite manufacturing expertise. Together, the companies are delivering scalable, lightweight, and high-performance protection systems tailored to the demanding needs of next-generation aerospace platforms.
Materials innovation meets aerospace engineering
At the core of the LEEF project is a thin, precisely controlled electro-deposited metal layer developed by Ultima Forma. Using a low-energy, near-room-temperature electrodeposition process, the company has created protective coatings that are not only exceptionally durable — withstanding temperatures up to 900°C and over 1,000 hours of salt spray testing — but also environmentally efficient, with a low carbon footprint and zero material waste.
These electroformed layers are seamlessly integrated with composite aerofoils produced by Polar Technology, using co-moulded or secondary bonded methods that enable both rapid manufacturing and retrofit compatibility. This approach offers a high level of design flexibility and is well-suited to scale, aligning with the increasing demand for propeller and rotor blade systems driven by the rise of eVTOL and UAV platforms.
Real-world aerospace applications
So far, the LEEF project has identified three core use cases where the technology delivers significant advantages:
- Rotor and propeller blades for eVTOL and UAV applications
- Fixed aerofoils for wing leading edge
- Outlet guide vanes for aircraft engines
Each use case is based on geometries provided by leading aerospace and defence OEMs, pointing to clear routes to market and commercial readiness. From ISR drones to large tactical transports, LEEF enables lighter, more durable structures that stand up to harsh operational conditions – including rain, ice, sand, bird strikes, and high-speed debris erosion.
Partner perspectives
Daniel Chilcott, Business Development Director at Polar Technology, commented:
“It’s fantastic to see the progress with this project. The close collaboration between Polar Technology and Ultima Forma is leading to solutions that could truly benefit the industry. The market is striving for scalable solutions without compromising performance or quality — this technology is helping to make that a reality.”
Steve Newbury, CEO at Ultima Forma, added:
“The LEEF project has already proven its potential with the production and testing of high-performance components. By combining lightweight composites with tailor-made electroformed protection, we’re delivering a unique, sovereign capability for the UK’s aerospace and defence sectors.”
Looking ahead
With scalable manufacturing now underway and interest growing from major aerospace and defence organisations, LEEF represents a critical step forward in UK-based innovation, strengthening the domestic supply chain and reducing reliance on overseas technologies.
As the industry moves toward lighter, more sustainable and high-performance flight platforms, Ultima Forma and Polar Technology’s partnership stands at the forefront of that evolution.
This project is partially funded by Innovate UK.
Their continued support has been instrumental in enabling Ultima Forma’s growth across multiple areas of innovation.
Check out our video case study to see how Innovate UK has supported Ultima Forma across a range of projects – helping us to expand our capabilities and accelerate towards a more sustainable future.
About Polar Technology
Polar Technology is a UK-based engineering and manufacturing business delivering high-performance composite and metallic solutions to global customers.
This project is partially funded by Innovate UK. Their continued support has been instrumental in enabling Ultima Forma’s growth across multiple areas of innovation.
Check out our video case study to see how Innovate UK has supported Ultima Forma across a range of projects – helping us to expand our capabilities and accelerate towards a more sustainable future.
