Cleantech innovator Uplift360 and Leonardo have achieved a breakthrough in sustainable materials recovery by converting an end-of-life helicopter rotor blade into a prototype drone arm. The project demonstrates how chemical recycling can transform high-performance aerospace waste into reusable, mission-ready materials.
Using its proprietary ChemR low-temperature chemical recycling process, Uplift360 extracted high-quality carbon fibre from a rotor blade originally used on an EH101 helicopter, a predecessor to Leonardo’s AW101. The reclaimed fibre was then repurposed into a structural component for a drone prototype, proving that chemically recycled composites can match the performance of virgin materials. Once destined for incineration or landfill, the rotor blade has become a showcase for how advanced recycling can close the loop on critical materials in Defence and Aerospace applications.
The project began under an R&D contract with Leonardo in May 2025, designed to test ChemR’s ability to handle complex composite waste. According to both partners, Uplift360 exceeded expectations—not only recovering the carbon fibre but also validating its use in manufacturing. The success highlights a practical pathway for reintroducing end-of-life components back into the production cycle.
The initiative directly supports the UK’s Strategic Defence Review, which emphasises the need for stronger domestic supply chains. Carbon fibre is a critical resource for aerospace and defence systems, yet the UK currently lacks sufficient recovery infrastructure. Uplift360’s ChemR process offers a homegrown solution, turning waste into a secure, circular resource for national industries.
Commenting on the project, Sam Staincliffe, Co-founder and CEO of Uplift360, said: “At Uplift360, we believe advanced materials should never go to waste. This project with Leonardo shows how ChemR can turn what was once unrecyclable into mission-ready material – supporting a more resilient and sovereign Defence supply chain.”
Clive Higgins, UK Chair and CEO of Leonardo, added: “Material recirculation is a key component of our Leonardo Sustainability Plan, helping us to reduce waste and reuse materials where possible, ultimately building resilience in our supply chains. Collaborating with innovators such as Uplift360 demonstrates how sustainability not only creates positive environmental and social impacts but delivers business and economic benefits.”
By transforming a retired rotor blade into a functional aerospace component, Uplift360 and Leonardo have provided a tangible example of circular innovation in action—one that could redefine how critical materials are recovered, reused, and revalued across the UK defence sector.
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