Leonardo and Uplift360 have transformed a decommissioned EH101 helicopter rotor blade into a prototype drone arm, advancing the recovery and reuse of critical materials for Defence and Aerospace.

Using its ChemR low-temperature recycling process, Uplift360 extracted high-quality, reusable carbon fibre from the rotor blade which was destined for incineration or landfill. The reclaimed fibres were repurposed into a structural component, proving the performance and viability of chemically recycled aerospace-grade composites.

The project, launched under an R&D contract with Leonardo in May 2025, focused on assessing ChemR’s ability to process complex composite waste. Uplift360 exceeded the brief by not only recovering material but validating its reusability in manufacturing. The results demonstrate how end-of-life components can return to the value chain, supporting sustainability and resource security.

This initiative aligns with the UK’s Strategic Defence Review, which prioritises supply chain resilience. Carbon fibre is vital to aerospace and military production, yet domestic recovery capacity remains limited. ChemR contributes to bridging that gap by turning waste into a secure national resource.

“At Uplift360, we believe advanced materials should never go to waste,” says Uplift360 co-founder and CEO Sam Staincliffe. “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.”

“Material recirculation is a key component of our Leonardo Sustainability Plan,” adds Leonardo UK chair and CEO Clive Higgins. “Collaborating with innovators such as Uplift360 helps us reduce waste, reuse materials and deliver environmental and economic benefits.”