Services offered

From first concept to full-scale production — collaborative engineering, trusted R&D, and advanced manufacturing.

At Ultima Forma, we don’t just supply components — we help design, validate, and manufacture the next generation of high-performance systems.

Our services cover every stage of development, backed by proven electroforming expertise and advanced modelling tools.

1. Contract R&D

Confidential development - innovation without risk to your IP.

We collaborate with customers under strict Non-Disclosure Agreements, ensuring intellectual property protection throughout the project and beyond.

Our team will conduct desk research, develop new processes from a broad scope of materials, then engineer these into products to meet your specific performance and cost goals.

What you gain:

• A trusted partner for confidential early-stage research
• Access to Ultima Forma's proprietary manufacturing process IP
• Access to advanced digital CAE and AI design tools
• Access to extensive materials science, electroforming and related manufacturing processes.

2. Design & Consulting

Helping you unlock the full potential of electroforming and associated processes.

Electroforming offers unmatched design freedom — complex geometries, thin parts, seamless structures, varying thicknesses and functionally graded materials that conventional manufacturing can’t easily achieve.

Our design and CAE teams help you realise that potential from the very start.

Our capabilities include:

• Design for electroforming: guidance on geometry, material choice, and tooling
• Coatings and thin shell systems: combining manufacturing processes and materials for optimal solutions
• Thermomechanical and hydrogen modelling: predict stress, heat flow and permeability
• HIP can modelling: optimise shape and thickness for uniform densification

What this means for you:

• Fewer design iterations and faster approval cycles
• Components optimised for both performance, manufacturability and cost
• Reduced technical risk before production

3. Manufacturing at Scale

From prototype to production — consistent quality, automated precision.

Once designs are proven, we can transition seamlessly to full-scale manufacture using our in-house automated lines:

Materials: Copper, Nickel, Nickel-Cobalt, Iron, Silver, Indium, combinations of these and others 

• Robotic Linear Line: reliable, repeatable electroforming for small-to-medium components
• Batch production for large components
• AMELE Line: high-rate system for mass manufacture of complex shapes

Why it matters:

• Scalable manufacturing within the UK, under ISO 9100 aerospace standards
• Consistent quality and reduced lead times
• Lower total cost through automation, multiple part and process integration