LEEF (Leading Edge Electro Forms)

Polar Technology have collaborated with Ultima Forma to develop a specialist erosion protection solution for defence and aerospace applications. Through combining their technologies, they have achieved improvements in the ability of carbon fibre composites to withstand the thermal and erosion requirements of the most demanding environmental conditions.
Leading edges of propeller blades and other aerodynamic structures are vulnerable to continual erosion from grit, sand, ice and water droplets, or damage in highly stressed areas encouraging crack propagation resulting in catastrophic failure. Protecting these areas with a thin layer of metal on the surface can extend the lifetime by a factor of 10.
Ultima Forma have developed the protection layer through a process of electro-forming, which involves electric currents depositing a thin layer of metal onto a substrate. Polar Technology are experts in design and manufacture of critical composite products and are working closely on the best method to integrate this electroform into the structure.
Scalable manufacturing of parts is underway, with the electroformed leading edges integrating seamlessly with composite aerofoils as co-moulded 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 and UAV applications, aerofoils for turbine inlets, and outlet guide vanes for aircraft engines.