polar-technology-management-group-ltd

Polar Technology partners with Trive Capital

Tue, 21 Apr 2026 08:06:36 GMT

Polar Technology are delighted to announce that they have secured additional growth capital from a new partner, Trive Capital, through a majority equity investment.

Trive Capital is a US-based firm with existing UK portfolio companies, with a strong track record of partnering with management teams to unlock transformational opportunities and support long-term growth.

David Stinnett, Partner at Trive, commented, “Polar has established itself as a differentiated supplier with vertically integrated engineering and advanced manufacturing capabilities that position it to solve complex, mission-critical challenges. The Company’s breadth of technical expertise allows it to draw from multiple disciplines to deliver innovative, high-performance solutions. We look forward to partnering with the Polar team to accelerate growth and further scale the platform.”

Scott Roberts, Co-Founder of Polar Technology, said, “We decided to partner with Trive due to their hands-on, partnership approach and proven track record of building highly differentiated manufacturing platforms. With Trive, we gain an experienced and collaborative partner who will enable our next phase of growth and advance Polar’s long-term strategic initiatives.”

About Trive

Trive Capital is a Dallas, Texas based private equity firm with more than $8 billion of regulatory assets under management. Trive focuses on investing equity and debt in what it sees as strategically viable middle-market companies with the potential for transformational upside through operational improvement.

The Trive team is comprised of seasoned investment professionals who have been involved in over 250 middle-market transactions representing in excess of $10 billion in revenue across Trive’s targeted industry sectors and situations.

If you have any queries regarding this story, please get in touch via our contact page.

Supporting the Next Generation of Lightweight, High-Performance UAV Structures

Fri, 17 Apr 2026 07:45:20 GMT

The UAV market is one of the fastest growing markets across the past decade and looks set to continue to its remarkable trajectory. Some projections indicate that it could contribute £45 billion to the UK economy alone by 2030.

This rapid development is being driven by a range of cross-industry applications, with UAV technologies being utilised to transform modern warfare, offering unique tactical advantages and enhancing operational efficiency; monitoring and maintaining energy infrastructure; and revolutionising logistics and delivery services.

In this competitive and fast-moving landscape, drone manufacturers are constantly looking to push boundaries and achieve improvements in lightweighting and performance. This is where Polar Technology are ideally positioned to support, providing a range of advanced manufactured components that are enabling the next generation of UAV technology.

Aerodynamic Composite Structures and Fan Blades

Composites offer huge advantages to UAV manufacturers, because of the significant weight savings they offer, as well as superior fatigue and corrosion resistance. These are essential attributes for manufacturers looking to maximise aerodynamic efficiency, increase flight endurance, and enhance payload capacity.

Polar Technology utilise advanced composite materials to develop active aerodynamic structures, which is applicable to many blade, fan or aerofoil applications. Furthermore, Polar have partnered with Ultima Forma to develop a Leading Edge Electro-Forms (LEEF) layer that further enhances erosion, impact and corrosion resistance.

To find out more, click here.

Transmission Shaft Technology

Polar Technology are market leaders in producing lightweight, energy-efficient transmission components, suitable for actuation and power transmission systems. Key to the approach is a patented mechanical interface that removes any reliance on adhesives, and can subsequently deliver high speeds and high torques.

To find out more, click here

Lightweight Hydrogen Cylinders

Many UAV manufacturers are exploring alternative fuels in the bid to reduce emissions, and hydrogen is front and centre of this evolution. Polar Technology specialise in lightweight hydrogen cylinders that offer a best-in-class weight efficiency and subsequently deliver a superior flight time.

The first production run of these cylinders is due this year, and they represent a key milestone in the development of Hydrogen technology, aimed specifically at the UAV market.

To find out more, click here.

Additive Manufactured Structures

Another way of making crucial weight-savings in UAV development is by utilising Additive Manufacturing techniques. This also facilitates the creation of complex shapes, with more flexibility than traditional casting methods.

Polar Technology produce DMLS (Direct Metal Laser Sintering) components made from a range of materials including Inconel, Stainless Steel and Aluminium, and then integrate those parts into wider assemblies or more complex components, combining them with our extensive machining and fabrication capabilities.

To find out more, click here.

Lightweight Fabricated Structures

Finally, Polar Technology manufacture fabricated tubular structures made from aluminium, titanium, and stainless steel. Polar are able to offer UAV manufacturers a highly accurate solution using qualified and experienced coded welders.

These materials are resistant to harsh environments and the structures can sustain extreme speeds and vibrations, making them ideally suited to the demands of the UAV market.

To find out more, click here.

If you have a question about a UAV project, and would like to speak to our team, please visit our Contact page.

The Importance of UK-Based SME’s in the Defence Industry

Fri, 23 Jan 2026 14:39:48 GMT

The UK Defence industry is undergoing its most transformative period since the end of the Cold War. The Government has announced the largest sustained increase in Defence spending in a generation, with the figure rising to 2.6% of GDP by the end of 2027.

This is a reaction to a fast-changing and increasingly volatile geopolitical landscape, with there being an urgent need to boost and reinforce the UK’s sovereign capability in light of the threat posed by Russia and the messaging from the United States that Europe needs to become more self-sufficient in regard to Defence spending.

As outlined in the Defence Industrial Strategy, the MOD will now commence wargames within the industry, to assess supply chain resilience and readiness for potential ramp-ups in rates of production.

Central to this new strategy is a renewed focus on SME’s, with the launch of a new Defence Office for Small Business Growth and a new SME Commercial Pathway. This should improve access and simplify entry points to major defence contracts for smaller businesses and is subsequently positioning these businesses to be at the forefront of this industry-wide transformation.

Chris Hague, Senior Policy and Comms Manager for Make UK Defence, the UK’s largest Defence industry association said the following: “ As the leading champions of the defence supply chain, we know that the UK defence industry is a foundational pillar of our UK deterrence. Defence companies across the country – from large primes, to mid-tiers, and SMEs - contribute to hugely to our security. Yet for too long the MOD has operated a peacetime procurement model that’s unfit for the challenges our country faces today.

“ The MOD must ensure its well-received Defence Industrial Strategy is not just another policy document, but rather delivers the reforms needed for the defence industry. This doesn’t just mean getting equipment into the hands of our Armed Forces faster, it means building, investing and expanding the supply chains beneath it, so we can scale production in a time of crisis. It means procuring to export so those supply chains are cheaper to maintain for the long-term. And it means making our industry more competitive by providing innovative SMEs and start-ups with a chance to win more direct MOD work.”

The Challenges

There are a number of potential obstacles standing in the way of this required transformation, including the complexity and rigidity of existing Defence supply chains. With a complicated system that spans multiple tiers and a myriad of sub-components, it has become increasingly difficult to accurately map supply chain networks and manage them efficiently.

Furthermore, these systems are ill-suited to accommodating new and emerging technologies, as well as utilising ‘dual-tech’ technologies that have been developed from other applications. This is why the major Defence organisations are actively looking to diversify their supply chains and identify suppliers who can solve challenges and fill gaps in their existing networks.

Equally important is the increased requirement for localised manufacturing capability. Due to conflicts such as the Russia-Ukraine war, global trade networks have been disrupted, whilst the new geopolitical landscape has increased the risk of price increases and even shortages of critical components.

The government’s Defence Industrial Strategy pledges that it wants to use this increased investment into the Defence industry as a “vehicle for growth” for the wider economy, and using UK-based suppliers is fundamental to achieving that goal, as it increases the number of available skilled jobs and directly contributes to GDP. A strategy of localisation is not just a risk deterrent; it’s an opportunity to actively boost economic growth.

The final challenge facing this transformation is the prevalence of non-competitive or single-source contracts. This was highlighted in the Defence Industrial Strategy, who pinpoint ‘lack of competition’ as one of the key obstacles to overcome. Competition drives innovation and efficiencies and provides greater value for the market as a whole.

Single-source supply also increases the risk of singular points of failure, with whole assemblies sometimes entirely reliant on specific sub-components. Risks include data breaches or cyber-attacks, with there being high-profile examples in recent years of attackers targeting the supply chain of the larger Defence organisations to disrupt production. Implementing a dual-source strategy on as many programmes as possible is essential for ensuring the long-term stability and success of the UK Defence industry.

The Solution:

Accelerated and supported by the launch of the Defence Office for Small Business Growth and the SME Commercial Pathway, UK-based SME businesses like Polar Technology offer many of the solutions to the challenges outlined above.

The main reason for this is that SME businesses possess inherent speed and agility. Without the complexities commonly associated with the larger Defence Primes, SME’s can respond quickly to changing demands and adapt and innovate continuously. This ‘superpower’ is a useful weapon that can solve existing supply chain issues and enhance the overall quality of the technology we provide the armed forces.

Similarly, the broad and diverse capabilities of SME’s means that often multiple components can be produced and combined by one supplier, in the form of complete sub-assemblies. For example, Polar Technology manufacture multiple elements of the Striker II™ Helmet project. This reduces the aforementioned supply chain complexity and minimises the risk of potential disruptions.

Finally, using UK-based SME’s not only mitigates the risk of geopolitical issues affecting global trade networks, but also makes data security easier and even helps achieve social value initiatives . For ‘Official’ and ‘Official Sensitive’ projects, there are specific security requirements that favour using UK businesses, whilst many MOD contracts now also have required social value goals, and SME’s are perfectly positioned to help achieve them, due to the fact they are often already key members of their local communities, with established social value goals of their own.

Conclusion:

It is clear that is an exciting, precipitous moment for the UK Defence Industry. Significant backing has been promised by government, and there is a well-defined plan of how goals are going to be achieved. However, the Defence Investment Plan (DIP) has been further delayed, after it was supposed to be published last summer, which is holding back the necessary investment into the UK Defence industry, and the subsequent trickle down of funding to the supply-chain.

As outlined above, it is businesses like Polar Technology who are perfectly-placed to tackle the challenges currently facing this proposed transformation, and ensure safer, simpler and superior supply chain networks for the industry going forwards, and this must be embraced and utilised by the government and the Defence industry as a whole.

To find out more about Polar Technology’s product portfolio for Defence, click here .

Polar Technology In The Community

Mon, 17 Nov 2025 16:07:44 GMT

Polar Technology are proud to be an active part of our local community in Eynsham, Oxfordshire.

Eynsham is a small, ancient market town just five miles outside of Oxford and still retains much of its medieval heritage.

Since moving to our cutting-edge, 180,000 sq ft facility, we have supported a number of local initiatives and raised money for different local charities, as well as contributing to local business collectives to represent the science and technology business community within Oxfordshire.

The initiatives we have supported include:

Headline Sponsors of the Eynsham 10K Run

Polar Technology have been the headline sponsor of the Eynsham 10K for the past ten years, with the event taking place on the 30 ^th November this year, organised by local running group, the Eynsham Road Runners.

As part of the sponsor package, we always have places available for employees to take part in the run, and there will be ten members of Team Polar running this year!

More details can be found here: Eynsham 10k Race | Eynsham Road Runners

Donations to Eynsham Museum and Heritage Centre

Polar Technology recently donated three samples to the Eynsham Museum and Heritage Centre, to form part of their exhibition, “Eynsham from Prehistory to the 20th Century”, which showcases some of the wonderful objects that bring to life Eynsham’s long and distinguished history.

Our donations included an exhaust system, transmission shaft and prop shaft, to give a few examples of the innovative and engineering manufacturing that is currently happening at our site.

More details can be found here: https://eynshammuseum.org.uk/

Supporting Local Charities

Each year, Polar Technology employees vote to select a local charity for the company to support, through raising money at various fundraising events. For 2025, the chosen charity is Helen and Douglas House, a local hospice for local children, living with life-limiting and terminal conditions, and their families.

The fundraising events that we have taken part in include the Oxford Half-Marathon, selling raffle tickets at our Summer BBQ’s, bake sales, craft fairs and much more!

To find out more about Helen and Douglas House, click here: Home - Helen & Douglas House

More details on our activities outside of the workplace can be found on our ESG page.

Five Benefits of Filament Winding

Tue, 04 Nov 2025 08:46:32 GMT

Polar Technology are market leaders in the process of filament winding, creating specialist, lightweight composite components which are ideally suited to the demands of high-performance industries.

Polar Technology will often then incorporate this composite part into a wider assembly, in many instances joining the composite to metallic elements using a patented mechanical interface.

Filament winding is a specialist technique, which involves wrapping continuous fibres around a rotating mandrel or part. Polar Technology have advanced filament winding facilities, including six custom-designed, CNC controlled machines, and can produce components with either a wet-wound process or with pre-impregnated material. For more information on our full capabilities, click here

There are many benefits to filament winding as a manufacturing method, including:

Produces Lightweight, Durable Components

Filament winding produces composite components with excellent strength-to-weight characteristics. This is ideal for the demands of industries such as aerospace, defence, automotive and motorsport. The resulting properties of the part can help to improve payload capacity, maximise pressurised gas/fluid storage, contribute to a higher operating speed for rotating parts and optimise the available space envelope. Filament wound composite parts also offer greater fatigue and corrosion resistance than metallic equivalents, making them a more reliable, durable alternative.

Enhanced Precision and Consistency

Polar Technology’s cutting-edge filament winding facilities allows for CNC automated, repeatable manufacturing. They have recently installed a brand-new, custom-made high-volume machine, with precision tension control and simultaneous, 3-spindle winding, that can accommodate parts up to 6m in length. This allows for rapid, high-volume production and subsequently reduces labour costs and cycle times.

Material Efficiency

Another advantage of Polar Technology’s filament winding facilities is the amount of fibre and resin that can be precisely controlled at high volume rates, through our 9-tow fibre delivery system, which minimises material waste, leading to cost savings for customers and ensuring a more sustainable process.

Flexibility of Fibre Orientation

Flexibility is central to the filament winding process, as a wide variety of laminates can be generated using a multitude of fibres, offering the capacity to tailor fibre orientations to fit the specific requirements of the end application.

Polar Technology are specialists in both hoop and helical winding, with hoop winding providing maximum circumferential strength. Helical winding allows for control over the mechanical properties of the composite material to balance between axial and circumferential strength. Polar Technology utilise this capacity to produce complex components such as launch tubes, rotor retention sleeves, pressure vessels and transmission shafts.

Integration with Metallic Sub-Components

Another key area of expertise at Polar Technology is in the integration of filament wound composite components with metallic end fittings. Our patented composite to metallic mechanical interface removes reliance on adhesives, thus reducing risk of fatigue maximising durability.

Assembly and joining processes are supported by designated manufacturing cells, which includes slitting, measuring, pressing, balancing and torque testing facilities, turning the tubular composite structures into turnkey transmission shafts.

Our filament wound product portfolio includes transmission shafts for aircraft engine and actuation systems , pressure vessels and hydraulic accumulators and retention sleeves for electric motors.

If you have a project that you think would be suited to the filament winding process, you can speak to our team by clicking here

Five Benefits of Advanced Precision Fabrication

Tue, 14 Oct 2025 11:55:10 GMT

Advanced, precision fabrication is one of the key areas of expertise we possess at Polar Technology, with our skilled fabrication department having generations of experience in producing durable, enabling metallic assemblies

Polar Technology utilise a range of fabrication techniques, including laser cutting, tube manipulation, press forming, hydroforming, TIG, MIG and resistance welding, integration of machined and additive components and final machining to solve complex challenges and meet the requirements of our customers. For more information on our capabilities, click here

Key benefits of Polar Technology’s advanced precision fabrication include:

Enhanced Customisation and Flexibility

Fabrication allows for high levels of customisation, meaning it is suitable for products with specific and demanding specifications. Using our unique in-house tube manufacture capabilities, we can take flat-sheet metal and form into tubes of up to 500mm diameter. This is particularly helpful in instances when the economics do not justify a mill run of tubes. Furthermore, our laser scanning equipment allows us to effectively reverse engineer products where a customer wants to replicate existing hardware but the design or data doesn’t exist.

Strong, Durable Products

Fabricated components are reliable and durable, and therefore suited to harsh environments where extreme temperatures, highly corrosive conditions and severe vibration loads are experienced. This is due to the strength of the materials used and the skills of our engineering and coded welding teams.

Suitable for Low and High-Volume Production

We implement poke-yoke electronic data capture and automate our manufacturing processes whenever possible to ensure repeatability and maximum quality control., Supporting Polar Technology is a very capable supply chain, including high volume investment casting which enables the business to accommodate projects with large production volumes.

However, where fast-make, lower volume production is required, we can utilise novel processes like our patented hydroforming process, HydroLite™, to reduce lead times and tooling costs, and provide a more cost-effective, faster option.

Wide Range of Exotic Materials

Fabrication is suitable for a variety of high-grade materials, including Inconel 625 and 718, Aluminium, Titanium and Stainless Steel. All of these metals are resistant to extreme and corrosive environments, prolonging performance and longevity. Furthermore, we are agnostic with materials and if a customer is not specific our expertise means we are able to advise customers on the most suitable material for their application.

Integration with Additive Manufacturing

Polar Technology doesn’t limit itself to only using traditional fabrication methods and is embracing emerging techniques such as integrating components developed and manufactured using DMLS (Direct Metal Laser Sintering) within a larger fabricated structure or assembly. This provides even greater flexibility, supporting thin wall sections, improving accuracy and eradicating tooling when it comes to creating complex geometries.

These benefits have allowed us to develop a comprehensive, wide-ranging portfolio of fabricated products, including safety critical structures, exhaust and fluid conveyance systems, thermal cladding and heat shields. For more details, click here

And if you have a project that requires fabrication expertise, you can speak to our team by clicking here

Polar Technology win Trailblazers Award

Mon, 15 Sep 2025 12:37:19 GMT

We are delighted to announce we have been selected as a 2025 Wired Trailblazer by WIRED Magazine and HSBC UK.

Now in its fourth year, this prestigious award celebrates the UK's most innovative businesses and is building a community of fast-growing scale-ups tackling today's social, economic, and environmental challenges.

The reasons behind our selection include our pioneering work in advanced engineering and dedication and our commitments to apprenticeships and training. The selection committee also specifically highlighted our potential to tackle some of the world's most pressing challenges through the development of composite materials.

As part of the awarding, our Managing Director, Paul Janes, attended an event with our fellow trailblazers at St Hilda’s College in Oxford, for a morning of breakfast, inspirational talks, networking, and a discussion on scaling a business.

Paul said on the awarding: “We are proud to be acknowledged as a Wired Trailblazer for 2025. This award is recognition of our rapid and sustained growth in the last few years and our commitment to tackling global challenges in the industries we serve. It was a pleasure to attend the event with our fellow winners.”

To find out more about the Trailblazers awards, click here.

To find out more about our commitments to solving global challenges, please visit our designated E.S.G page.

Ultima Forma and Polar Technology’s leading edge protection layer enhancing durability for aerospace and defence applications

Mon, 01 Sep 2025 10:11:06 GMT

Last year, Ultima Forma and Polar Technology announced the launch of the LEEF (Leading Edge Electro Forms) project, collaborating to improve the ability of a composite structure to withstand erosion, impact and corrosion in extreme operating conditions.

The project has gone from strength and strength and is now attracting interest from leading Aerospace and Defence organisations, who are exploring potential applications for the technology.

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.

All aspects of the process can be carefully controlled, with the thickness and dimensions being tailored depending on the application. The ambitions behind the project are to develop a UK-based manufacture and distribution network for leading edge protection solutions including the manufacture of the composite structure itself which will ultimately shorten and simplify the supply chain process.

A number of milestones have been hit since the project launched, including the Nickel-Cobalt LEEF layers maintaining exceptional hardness when tested up to 900°C and beyond 1000+ hours of ASTM B117 salt spray testing, delivering unparalleled performance for high-temperature platforms and mission-critical components.

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.

All three cases are based on geometries provided by leading OEM customers in the aerospace and defence industries, which illustrates the planned routes to market. From the smallest ISR drone to the largest tactical transport, LEEFs deliver lightweight, high-durability protection against rain, ice, sand and bird strikes.

Daniel Chilcott, Business Development Director at Polar Technology said “Its fantastic to see the progress with this project and close collaboration between Polar Technology and Ultima Forma leading to solutions that could really benefit the industry. We know the market is striving for scale on a competitive level without compromising on performance or quality. This technology and collaboration has the potential to make this a reality.”

Steve Newbury, CEO at Ultima Forma said “The LEEF project has already produced and tested parts to prove out the potential in this flexible barrier technology. Bringing together lightweight composites with thin tailor-made electroformed protection delivers a unique sovereign capability for the UK’s aerospace and defence sectors”.

Read the original article on the project here.

Or to speak to our team about a potential end application for the technology, click here.

Polar Technology selected by ISTEC to manufacture the sub-frame for the USAF Grey Wolf helicopter weapon integration mounts

Mon, 01 Sep 2025 10:11:04 GMT

Polar Technology have been selected by ISTEC, one of the UK’s leading designers and manufacturers of specialist weapons integration mounts, to manufacture the sub-frame required to connect the ISTEC designed weapons mount to the United States Air Force (USAF) Grey Wolf Helicopter.

The USAF Grey Wolf helicopter is a Boeing-led programme for the replacement of the famous, but aging, UH-1N Huey helicopter and is built on a Leonardo AW-139 platform. ISTEC delivered the first shipsets (made up of a left and right gun mount pair) to Leonardo in late 2024 as announced in their press release.

Polar Technology was selected as the supplier for the sub-frame needed to connect the weapons mount to the airframe due to their proven expertise in advanced, precision and critical fabrications. They manufactured the frame at their cutting-edge, 180,000sq ft facility. The project posed some significant challenges, with the frame subject to rigorous manufacturing standards required by the aircraft safety critical installation.

Polar Technology was involved at the project outset, supporting several ISTEC design iterations and manufacturing reviews. The manufacturing process involved many of the key capabilities Polar Technology possesses, including precision bending aluminium tubing, machining of sub-components.

At the final assembly stage, Polar Technology also utilised precision manufacturing and calibration of jigs and fixtures, and coded welding. Each completed frame was delivered to ISTEC with the necessary quality pack to ensure full traceability of each component and process, to ensure all raw materials sourced are to aerospace release.

Mick Coulson Managing Director ISTEC said, “Polar Technology are an ISTEC approved AS9100 supplier who, along with a strong ISTEC supply chain continue to support ISTEC with the ongoing Grey Wolf weapon mount program.”

Daniel Chilcott, Business Development Director at Polar Technology said: “Polar Technology is delighted to have supported ISTEC with supply of this critical assembly for the USAF MH-139A, a fantastic platform enhancing US security and defence. It’s been a great example where Polar has been able to draw upon it’s turnkey capabilities, significantly simplifying the supply chain for ISTEC. We hope to identify and support similar projects in the future.”

To find out more about our Defence product portfolio, click here.

Or to speak to our team about a new project, click here.

Image Caption: USAF Grey Wolf fitted with ISTEC Weapons Mount (Using Polar Technology manufactured Sub-Frame) – image credit Senior Airman Mary Bowers, Malmstrom AFB Public Affairs

From Concept to Solution: A Guide to How We Support our Customers

Mon, 11 Aug 2025 13:13:19 GMT

At Polar Technology, we take a project from concept to solution, partnering with our customers to identify the right technology and manufacturing method for the end application, before managing every stage of the process all the way through to volume production.

The key stages include:

Understanding Requirements

The first step is our experienced engineering team will immerse themselves in the project to establish a detailed picture of the product requirements and the operational environment.

Our expertise in a diverse range of specialist processes such as filament winding, hydroforming and additive layer manufacturing allows us to offer innovative solutions to customer problems and suggest the most cost-effective, efficient method for manufacture.

Partner or Lead the Design

The design and development stage is tailored entirely to the requirements of the customer. In some cases, we collaborate as a partner, assisting with elements of the design, whilst in others, we take full responsibility for the design of the product.

In either case, our 3D CAD (Computer-Aided Design) software allows us to take an initial specification and bring it to life as a detailed 3D model. We can also offer Finite Element Analysis (FEA) to assist with preparing the design, ready for review and approval by the customer. We also have the capacity to reverse engineer an existing component with our laser scanning capability, producing a CAD model that can facilitate new or additional design features.

Develop Technical Solutions

Furthermore, our in-house design tools, analysis, FEA capability and mechanical testing laboratory allows us to demonstrate product performance and calibrate design methodologies, ensuring that every product is optimised before it goes to the volume production stage.

Alongside this, we also have extensive tooling design and manufacture capabilities, enabling us to optimise the tooling design to accommodate larger volume projects and ensure the production rate is met.

Manufacture

When the project reaches the manufacturing stage, our state-of-the-art Poka-Yoke production management software ensures that quality is maintained throughout.

This includes a fully electronic travel system with real time data capture, a PFMEA derived process and control plan, and strict adherence to industry quality standards, including AS9100 and ISO9001:2015 certifications.

Deliver Excellence

We understand that, at the forefront of cutting-edge engineering, requirements can change. This means we ensure we can remain flexible, but when it comes to a finalised product, we pride ourselves on being Right First Time, On Time in Full, Every Time.

We also operate in a culture of continuous improvement, and work with our customers to identify areas where we can further streamline and enhance our in-house processes.

Aftersales Support

Our work doesn’t end when the product is delivered. Our aftersales support will ensure the partnership continues, assisting with any further queries as the product continues up the supply chain.

This is one of the reasons that we have built a number of long-term, well-established relationships with market-leading customers, with some lasting as long as twenty years.

For more information on our full range of engineering services, please click here.

Or, to find out about how we can assist with your enquiry, please visit our Contact page.

Polar Technology Operating at Pinnacle of Automotive Excellence

Thu, 24 Jul 2025 09:20:51 GMT

With the recent showcasing of the latest innovations in the automotive industry at the Goodwood Festival of Speed, it seems a fitting time to highlight the role our composite and metallic components play in the sector’s continual pursuit of high-performance.

We have been enabling technologies in high-performance vehicles for over 10 years and have become a trusted, reliable partner for our market-leading customers. Our flexibility, quick turnaround times and superior quality have kept us at the forefront of the industry.

We support our customers through the initial design phase if desired, ensure consistent manufacture, take care of all tooling and then go on to manufacture high quality parts.

We have also adapted our offering to match the innovation and changing demands of modern consumers, developing solutions tailored to the electric vehicle and alternative fuel markets. More information can be found on our Energy Transition page.

Our product portfolio includes:

Body Work and Structural Composite Assemblies

Utilising our expertise in moulded composites, we have become experts in developing and manufacturing structural active and aerodynamic assemblies that generate greater levels of downforce and optimise performance.

Furthermore, we also have a specialist in-house paint shop that can accommodate high-spec visual components, ensuring our components are delivered to our customers as finished, turnkey solutions.

Composite Transmission Shafts

We are renowned for our expertise in composite transmission shafts. We design and manufacture the composite tube to exacting customer requirements, before joining to metallic fittings through our proprietary joining technique, which is robust and fatigue-free and requires no adhesives.

Typical applications include driveshafts for EV vehicles and propshafts where we can tailor stiffness, weight and torque carrying capability.

Exhaust Systems

We are established leaders in the manufacture of exhaust systems, using both traditional fabrication, hydroforming and additive manufacturing techniques. Our systems enhance engine performance, through the incorporation of tapered features to support tuning and back pressure and dampen tortional vibrations.

Our additive manufacturing capabilities enable complex geometries, wall thicknesses down to 0.5mm, and can be welded and integrated with conventional fabricated parts. We also offer a comprehensive build strategy, including all post-processing requirements such as heat treatment, support removal and precision 5 axis machining.

Lightweight and Structural Subframes

We have an extensive team of highly skilled technicians welding and fabricating structural metallic assemblies from structural steels like 15CDV6, S355, Titanium and in some cases Aluminium. Strict tolerances are maintained through fixtures and finish machining where necessary.

Furthermore, final steps of QC can include NDT such as dye penetrant or MPI of critical welds.

Hydraulic Accumulators

We supply composite hydraulic accumulators for use in suspension systems and gearbox actuation. Our solutions are tailored to the customer’s exact requirements, with different designs available depending on the pressure ratio, fluids present and the temperature range.

Our Type 3 composite accumulators typically operate in a pressure window of 300-350bar where they offer 50-60% weight saving compared to a metallic equivalent.

For more information on our full offering to the Automotive industry, click here.

Or to speak to our team about a specific project, please visit our Contact page.

25 Years of Engineering and Manufacturing Excellence

Mon, 30 Jun 2025 13:46:06 GMT

The heritage of Polar Technology has recently reached the twenty-five-year mark. From its origins in 2000, the company has evolved from a small, specialist fabrication business into a global supplier for market-leading customers across a diverse range of high-performance industries.

Since taking over the business in 2012 and introducing the Polar Technology Group, co-founders Mike Dewhirst and Scott Roberts have utilised the existing engineering and manufacturing expertise and further diversified the product portfolio to include the series manufacture of proprietary, high valued-added composite and metallic products and systems. This transformation has included a move to a world-class, 180,000 sq. ft. facility in Eynsham, Oxfordshire.

Scott described the journey to this point: “When Mike and I took over the business, it was in a very different place to where it is today. The company employed around 20 people and was located on a small site called Sutton Farm.”

“What struck us both immediately was the extraordinary skill of the fabricators in manufacturing highly complex exhaust systems and heat shields for the motorsport industry and how, with a bit of investment, this could be grown into a much larger business supplying products across the motorsport, high performance automotive, aerospace, defence and medical industries.”

“That fabrication business, along with its sister composites business, now form part of the £30m-turnover, 250-employee-strong Polar Technology Group that we are today. Many of our original colleagues are still with us and have received acknowledgement for their contribution through the long-service award scheme, with some recently reaching the twenty-year mark.” You can find out more about the awards here.

Finally, Scott was keen to stress that there is still much more to come: “There is still much to do in improving the capability of the business, but the outlook for the next 5 years is excellent, with a strong, diversified order book and a growing market full of opportunities. Here’s to the next twenty-five years!”

For more information about our heritage, please visit our About page

Polar Technology awarded Breakthrough Culture Award

Fri, 23 May 2025 07:34:31 GMT

Polar Technology are delighted to announce that we have been selected for the Breakthrough Culture Award: Growth Edition in 2025. The award is a 12-month certification designed to recognise the next wave of UK companies who are passionate about creating a thriving workplace.

The Breakthrough Culture Awards are run by Hyer, a global media company and internet publisher focusing on workplace innovation and company cultures. The Growth Edition is for growing companies that dared to build a culture they're proud of and that believe a thriving team equals a thriving business.

This award is testament to Polar’s commitment to building an employee-led culture, their investment in training and development and their celebration of both individual and collective achievements. That culture is built on the foundations of dedication, empowerment, innovation and integrity.

This approach has been centred around understanding from employees what is important to them and what they value most about the business, and then using this insight to alter and improve Polar’s Employee Value Preposition (EVP).

Furthermore, Polar Technology have introduced a programme where their customers visit their site, or their employees attend events held at customer workplaces, to give employees a chance to witness the end results of their efforts. All internal communication channels, including newsletters and town hall meetings, are geared towards this goal, ensuring that every Polar employee understands that all processes have a clear purpose and serve an important function.

A powerful example of this was an incident when the life of a prominent Formula One driver was saved, after a horrific crash, by the Halo- a specialist metallic driver protection system that was previously manufactured at Polar Technology. That specific Halo could be traced all the way back to the individual who worked on the manufacture of the device, and the driver even sent a personal thank you.

Finally, another piece of employee feedback that was used to inspire change at Polar was the implementation of an internal Leadership Academy. This was introduced to facilitate development of employees at differing stages of their career, giving them the skills to manage teams and develop their own leadership style. You can find out more about the leadership academy here.

Sharon Barrett, HR Director at Polar Technology, said: “Culture isn’t something you can manufacture—it’s the essence of who we are at Polar Technology. Our journey has been about peeling back the layers to truly understand what matters most to our people. Through open conversations and honest feedback, our employees have helped us uncover both our strengths and opportunities for growth.

"These insights are shaping a forward-thinking culture—one that not only reflects who we are today but also prepares us for the challenges of tomorrow. As we build on these strong foundations, our commitment to being the best company to work for remains stronger than ever.”

To find out more about the culture at Polar Technology, please visit our Careers page

Our Solutions for a Sustainable Future

Thu, 08 May 2025 08:41:48 GMT

As part of our vision to create enabling technologies for a sustainable and healthier future, Polar Technology have focused on the development of products for alternative, clean energy sources supporting the transport sector’s move to electrification.

To underline the challenges that the transport industry faces as the journey to Net Zero accelerates, the sector was estimated to be responsible for 30% of the final global energy demand in 2019, with approximately 95% of that demand met by fossil fuels. That figure has been reduced since, thanks to the growth of renewable transportation solutions.

Indeed, OneEarth, a leading sustainability research organisation, has identified certain energy delivery solutions that are fundamental to the transition to renewable transportation, which include Green Hydrogen, Sustainable Biofuel and Electrification.

Through the following examples from our product portfolio, Polar Technology have positioned themselves as a key supplier within all the above categories in the ongoing clean energy revolution.

Hydrogen Storage:

Utilising existing expertise in lightweight, high-pressure vessels and hydraulic accumulators, Polar Technology have developed solutions in two different areas to address the challenges posed by storing hydrogen safely.

Firstly, they design and manufacture lightweight hydrogen cylinders that significantly increase the range of unmanned aerial vehicles (UAVs). These cylinders offer class-leading weight efficiency and can hold 25% more fuel than alternatives, which opens up numerous new markets and applications for UAV’s.

Polar have partnered with leading fuel cell provider, Intelligent Energy, on a landmark application for hydrogen-powered drones. Click here to find out more.

The second solution is the novel ‘Hydrogen in a Box’, which provides an innovative approach to more efficient hydrogen storage, thanks to significantly increased volumetric efficiency. This is achieved through a design that minimises the amount of empty or lost space within the vessel.

Polar are currently working on evaluating and certifying prototypes for both 350bar and 700bar applications and are exploring new partnerships to commercialise ‘Hydrogen in a Box’ for technologies in the aerospace industry. You can find out more about ‘Hydrogen in a Box’ here.

Bio-Methane Storage Tanks:

In a project that has valuable correlations to our work in Hydrogen, we have partnered with a leading clean energy company to develop cryogenic storage solutions for liquid bio-methane.

The tanks Polar provide store renewable bio-methane that is captured and processed from the manure produced on dairy farms and are then used to power cutting-edge farm equipment, facilitating a complete, cyclical model for producing sustainable fuel on British farms.

Battery Enclosures:

To support the move to electrification, Polar Technology develop lightweight composite battery enclosures made from high-temperature materials. These enclosures offer fire retardancy, structural rigidity and significant mechanical strength at a minimal weight.

These enclosures are enabling major breakthroughs in eVTOL (Electric Vertical Take-Off and Landing) technology, including supporting the first piloted thrust-borne flight manoeuvres of a leading eVTOL aircraft.

Polar employ the novel use of materials, coatings and finishes to produce a lightweight product and are able to deliver a fully-integrated, turnkey solution to their customers.

To find out more about our full portfolio of sustainable products, visit our Energy Transition page.

Or to find out about how we can enable your sustainable technologies, get in touch with our team here.

Polar Technology Powering Formula E for 2025

Mon, 14 Apr 2025 07:24:50 GMT

With the 2024-25 Formula E season well underway and the Miami E-prix having taken place this weekend, it’s a great time to look at the innovative and sustainable technology that is powering the world’s leading competition for electrically powered single-seater racing cars.

Formula E differs from Formula 1 in that the chassis is standardised, with each team competing with the same specification, but the development of other parts including the electric motor, inverter, gearbox, rear suspension and software can be specially designed by each team. This marks the design and development of the powertrain as one of the deciding factors in the battle to finish first in both the driver’s and constructor’s championship.

Polar Technology are the chosen supplier for a number of key components for selected constructors within Formula E and are helping to enable their technologies to maximise high-performance in an industry where every tenth of a second counts.

Utilising their expertise in advanced composite materials, as well as their strong background in motorsport and their ethos of focusing on technology that helps to build a sustainable future, Polar Technology are well-equipped to continue to expand their offering for Formula E in the coming years.

The products that are currently showcased on this season’s cars include:

Drive Shafts

As market leaders in the development of lightweight, energy-efficient transmission components, Polar Technology are able to design bespoke drive shaft assemblies, which are a crucial element of the powertrain of Formula E cars.

Their patented mechanical interface removes reliance on adhesives and can subsequently deliver high speeds and high torques with extreme durability, ensuring significant weight savings, increased safety and enhanced performance.

For more information on our transmission shafts, click here.

Rotor and Stator Sleeves

Electric motors are another vital part of the powertrain, with them serving the same purpose as the combustion engine in a F1 car, in terms of converting energy (supplied by the battery) into mechanical power.

This process provides challenges, with the motors required to rotate at high speeds and therefore generating high centrifugal force on the motor’s magnets. Polar Technology’s solution is optimised carbon-fibre sleeves, which work to retain the magnets and minimise the current losses. They have perfected a press-fitting technique that fit the sleeves to the motors directly, which enables a higher retention pressure.

The mating part to the rotor sleeve is the stator sleeves, which serve the purpose of maintaining the cooling medium of the stator pack. The combination of these parts offers the minimal air gap and offset between the rotor magnets and the stator, thus enabling optimum performance from the motor.

For more information on our sleeve solutions, click here.

Gearbox Housings

Gearbox housings within Formula E are the main structural element of the rear of the car, and are required to be lightweight, with strict regulations to follow. Polar Technology are well-placed to be the chosen supplier for this component, with an in-house moulded composites department, a precision metallic machining department and the equipment and experience to machine large complex components such as the entire gearbox housing.

They have developed a core manufacturing technique that allows the assembly to be produced with a single cavity tool, as opposed to assembling multiple smaller components together. Metallic elements can also be incorporated during the manufacturing process, with Polar possessing the capability to machine any required inserts in-house as well as machining and inspecting the final assembly.

Meanwhile, utilising Finite Element Analysis (FEA) in the design stage allowed Polar Technology to identify areas that needed strengthening, and where further weight reductions could be made, to ensure an optimised, turnkey solution is delivered to our customers.

Polar Technology are proud to be a part of the innovation occurring within Formula E, which is breaking new boundaries and pioneering future mobility in the electric vehicle industry.

To speak to our team about any queries you may have on any of the products mentioned above, visit our designated Contact page.

BAE Systems honors Polar Technology with a ‘Partner 2 Win’ Gold Tier Award

Thu, 10 Apr 2025 06:53:10 GMT

Polar Technology today announced it received a Gold Tier Award from BAE Systems’ Partner 2 Win program.

Polar Technology was selected from a pool of suppliers that delivered exceptional performance and contributions to support supply chain success for BAE Systems’ Electronic Systems sector in 2024, and the award recognises the high standard of quality and delivery achieved in their supply of the structural elements of the Striker® II Helmet-Mounted Display.

BAE Systems’ Partner 2 Win program is designed to achieve operational excellence and eliminate inefficiencies in its supply chain by raising the bar of performance expectations to meet the demands of current and future customers. As part of the program, BAE Systems meets regularly with its suppliers to transfer best practices and ensure the components and materials that compose its products meet the highest quality standards.

The Gold Tier is awarded to the suppliers who achieve 100% quality and delivery ratings over a 12-month rolling period.

“I want to sincerely thank our winning suppliers for their exceptional support and ground-breaking solutions that have set new standards in our industry,” said Jennica Dearborn, vice president of Operations, Electronic Systems. “We look forward to our continued collaborations that push the boundaries of what’s possible.”

About Polar Technology

Polar Technology are an engineering and manufacturing business providing technology-based solutions at the leading edge of composite and metallic technology. The high integrity composite structure and 3D printed optics frame assembly that form part of the Striker® II Helmet are evidence of Polar’s expertise in the manufacture of composite structures, which is just one element of their varied and growing portfolio for the defence industry.

Paul Janes, Managing Director at Polar, said: “We are delighted to receive this award from BAE Systems, as it is a testament to the high standards of quality and delivery that we pride ourselves on here at Polar Technology. This collaboration represents a flagship programme for our team and we’re proud to be continuing to support BAE Systems for the duration of the project.”

About BAE Systems

The Electronic Systems sector of BAE Systems is part of a global defence, aerospace, and security company. We deliver products and services for air, land, sea, and space, as well as advanced electronics, intelligence, security, and IT solutions and support services. Our dedication shows in everything we design, produce, and deliver— to protect those who protect us in a high-performance, innovative culture. We push the limits of possibility to provide a critical advantage to our customers where it counts.

To read more about our partnership with BAE Systems, read the full story here .

Or, to speak to our team, please visit our Contact page.

Our Solutions for the Defence Industry

Tue, 18 Mar 2025 09:11:04 GMT

The defence industry is one of our key end-markets at Polar Technology, and one currently undergoing significant growth.

Utilising our expertise in both composite components and advanced precision fabrications, we are able to offer enabling, durable and lightweight solutions that are ideally suited for critical, demanding applications.

In recent years, we have expanded our portfolio in defence products, announcing landmark partnerships with leading OEM customers like Supacat, BAE Systems and MBDA. These new contracts have been founded on tailored engineering support, automated, repeatable manufacturing processes and strict quality systems, further validated when we were confirmed as a JOSCAR-registered supplier.

Our products are now flying on fighter planes, storing battery energy for EVTOL’s, transferring torque within UAV’s and enhancing the safety of high-mobility land vehicles around the world, and we are only just getting started. The following is just a sample of our portfolio:

Safety Critical Structures

The integrity of safety critical structures in live theatre operations is essential for our Defence customers. We manufacture highly stressed weapon mount structures for helicopter platforms, and we are the named supplier of the enhanced safety roll-over protection assembly for the High-Mobility Transporter (HMT), a vehicle used in land operations by the British Army. These structures are made with a variety of fabrication methods, including tube manipulation, coded welding, precision machining and hydroforming.

We use materials that are resistant to harsh environments, such as aluminium, titanium and stainless steel, and that can sustain extreme speeds and vibrations. We also provide further processes, including heat treatment and non-destructive testing, meaning we are able to offer customers a fully integrated, verified, turnkey solution.

For more information, read our designated press release on our Supacat partnership.

Electronics and Communications Housings

Another long-term contract we have established is for a variety of configurations of communications housings for a recently commissioned armed, tracked based personnel carrier fleet. We manufacture aluminium housings from castings, extrusions and machined components.

These housings are welded, machined, inspected, and painted before being delivered to our Tier 1 customer. To support this contract, we invested in specific precision machining equipment, further demonstrating the strength of the partnerships we establish with our long-term customers.

Composite Blades and Fans

We have developed a range of lightweight, co-cured blades and fans, suitable for most impellor, fan and propellor applications. Our high-performance moulded department utilise specialist processing techniques for closed mould, foam core wings, blades and foils.

Furthermore, we offer innovative tooling solutions to meet specific customer demands, that can be optimised for different volumes and manufacturing processes.

Specialist Head Mounted Display Technology

We have supported BAE Systems in the design and development of the high integrity composite structure and 3D printed optics frame assembly for their Striker ^® II Helmet-Mounted Display. The helmet display is a pioneering solution to increase situational awareness for Royal Air Force Typhoon pilots.

The carbon-fibre structure acts as an enabling element within the display, as it is a lightweight component, without compromising on strength, whilst it facilitates the cutting-edge optical sensors that allows for the overlaying of virtual mission-critical data onto the real-world environment.

For more information, read our designated press release on our BAE partnership.

Actuation System Transmission Shafts

We provide filament wound composite structures on a long-term, classified UAV application. As market leaders in producing lightweight, energy-efficient transmission components, our products are designed to operate at extreme speeds and torques with infinite durability, making them ideally suited to the demands of defence.

Key factors within the manufacturing process are our patented mechanical interface that removes any reliance on adhesives, and our in-house curing and machining capabilities.

For more information on our wider portfolio, please visit our designated Aerospace and Defence page.

Or to speak to our team about a specific project, please visit our Contact page.

Polar Technology developing its future leaders with Leadership Academy programme

Thu, 13 Mar 2025 10:03:41 GMT

Polar Technology has established a specialist, in-house Leadership Academy to provide all current and future managers with the necessary skills for effective leadership.

The programme is designed to help participants understand their own strengths and find their own leadership style, as well as fostering their own personal growth. This programme enables our managers to build and cultivate high-performing teams and ultimately improve overall morale and productivity.

The Leadership Academy is divided into three separate levels, each with its own specific purpose and tailored content:

Personal Excellence is for individuals recognised as possessing high potential and supports them to increase their personal awareness and manage themselves effectively.
Management Excellence is intended for first-line managers and is focused on developing the skills, mindset and behaviours required to be an effective manager.
Leadership Excellence is designed for senior to middle managers to enable and support them to develop a ‘leadership mindset’ and equip them with the behaviours and skills needed to deliver high-impact results.

Sharon Barrett, HR Director at Polar, implemented the programme into the business and outlined her motivations for doing so: “I believe the key to great leadership and a strong organisational culture is promoting environments where teams trust each other and where collaboration is encouraged.”

“It is vital that we provide our leaders with the skills needed to inspire their teams. I am proud of the Leadership Academy we run here at Polar and the investment the business has made in this programme is testament to our view that developing talented people is absolutely fundamental to our success.”

The programme is delivered by Jayne Stoddart from RedKite Performance Coaching, who provides a flexible, blended-learning course that includes in-person workshops, virtual learning review sessions and personalised one-to-one coaching sessions.

Jayne has been working with Polar in some capacity for years and has trained roughly 30% of the workforce as they have gone through the various levels of the programme.

She described her experiences of delivering the programme: “The whole purpose is to support individuals to understand themselves better so that they can communicate better. You can only get the best out of others if you’re getting the best out of yourself.”

“What I have noticed in the individuals who have gone through the course is the increased appetite for learning, the positive attitude and the willingness to put what they have learned into action. That says to me that Polar is attracting the right talent!”

Chris, who works as a Technical Manager in Polar’s engineering department, described his experience of the course: “The personal excellence course by Jayne was an insightful course on managing my emotions and understanding how to communicate effectively. I am now mid-way through the management course which is helping me to build on my management skills.”

Meanwhile, Michelle who works as QESH Manager, said: "The Leadership Academy was a valuable development opportunity for me which broadened my skill set and allowed me to learn a lot about myself along the way."

To find out more about the career development opportunities available at Polar, visit our Careers page

National Apprenticeship Week: Cain and Luke's Stories

Wed, 12 Feb 2025 13:22:44 GMT

This week is National Apprenticeship Week; the UK’s annual commemoration of apprenticeships and skills, and the value that they bring both the apprentices and their employers.

Polar Technology has long been a big advocate of apprenticeships and training programmes, believing they offer a unique opportunity to find and nurture the best talent.

Two perfect examples of this are Cain and Luke, who work as Production and Project Engineers respectively. Ten years ago, Cain and Luke first joined Polar as apprentices, going on to complete both Level 2 and 3 Apprenticeships in Fabrication and Welding with the company.

Cain explained how the apprenticeship worked and how it offered him a unique insight into the business: “We were encouraged to rotate across all the various departments, completing 3-6 months in each. This was great, as it meant that you weren’t restricted to just one area or one skillset and meant that I was able to see how the business worked as a whole.”

After completing both levels of the apprenticeship after about 4-5 years with Polar, Cain and Luke decided that they wanted to keep learning and developing further, and spoke to Scott, the co-founder, about wanting to complete a HNC (Higher National Certificate). The company agreed to fund this further study, and their progression continued.

Luke explained how much he enjoyed the HNC: “I found it so interesting, there was much more of a technical element to it, and it meant I was much more aware of the broader engineering processes.”

Cain then took a further step, applying for a job in the drawing department whilst still working as a welder, and was successful. Both then pursued opportunities elsewhere, with Luke working as a Pit Mechanic for a motorsport company, a role he says he wouldn’t have got without the experience he had accrued at Polar.

However, their stories at Polar weren’t complete, with both returning to the company to take positions within the engineering office in the last couple of years.

Cain explained how he thought his apprenticeship still benefitted him in his current role: “It’s given me a really valuable way of looking at things, because I have seen multiple ways of working and have spent time in nearly every department of the production side of the business. Whereas some engineers are fresh out of university and therefore don’t necessarily think like the person who actually manufactures the part, the first thing I do is go and speak to our fabrication department and get their thoughts.”

Luke agreed, adding: “I’ve now got such a broad knowledge of nearly every single product we make, and I’ve also been in the operator’s shoes, meaning I understand the complete journey of a product, from initial design to final assembly.”

Polar Technology currently have four apprentices completing their qualifications whilst working at the company, across the machine shop, inspection and maintenance departments, and hopes to continue with the development pathways that Cain and Luke have benefitted from.

When asked what the best thing about choosing to undertake an apprenticeship at Polar is, Cain answered: “I think it’s the fact that you can clearly see the progression pathways ahead of you. And the fact that your ambition is matched by the company. If you say that you want to keep developing, they’re happy to continue supporting that.”

Luke had a different answer to the same question: “I think it’s also beneficial for both parties: the apprentices and the company. We get career progression, and the company gets experienced employees that they know they can trust. It’s a long-term investment but it pays off!”

To find out more about the apprenticeship and other training opportunities available at Polar Technology, please visit our Careers page

A guide to our innovative hydroforming process

Wed, 05 Feb 2025 09:13:31 GMT

Within the extensive capabilities for metallic processes and fabrications at Polar Technology is a novel, specialist hydroforming process.

Hydroforming is a process that utilises highly pressurised fluid in the formation and shaping of metal components. The benefits are that it offers a fast and accurate method for forming complex shapes, but historically it has been considered an expensive alternative to traditional fabrication methods, which is only suited to higher-volume manufacturing.

Polar Technology (under its metallic brand, SST Technology) developed the HydroLite® process to address industry needs and overcome traditional drawbacks. HydroLite® isa brand-new, robust means of carrying out hydroforming in vastly reduced lead times and with minimal tooling costs. This not only opened up the possibility of using the process at earlier stages of a product cycle, such as development and prototyping, but also ensures that hydroforming is now a viable, enabling option for low-volume fabrication.

A summary of the key benefits of the process are as follows:

Provides greater agility - With typical lead times ranging from 2 to 3 weeks, the HydroLite® process is suitable for fast-make, low-volume products and high-pressure industries.
Supports multiple iterations - The low tooling investment also means obsolescence is less of a concern to the designer since new tools can be quickly and cheaply redesigned.
Engineering support - We offer extensive design and process expertise throughout the process, building in design and manufacture and ensuring that we are offering our customers the most optimised solution for their requirements.
Improved consistency and quality - HydroLite® is a semi-automated process, capable of delivering accurate repeatability of complex forms with increased quality control.
Cost-effective - Low tooling costs and reduced investment in jigs often makes HydroLite® the most cost-effective option.
Repeatable thickness control - Enabled by in-house design simulation, with increased flexibility to accommodate design changes throughout the process.
Works with variety of materials - Ability to process exotic alloys such as Inconel, titanium and stainless steel, from simple or complex pre-forms.

Polar Technology continue to be market-leaders for hydroforming processes, supplying complex exhaust and pipework systems to multiple customers within the motorsport and automotive industries, with our systems incorporating tapered features which support tuning and back-pressure, non-symmetrical geometries and features that to dampen tortional vibrations. This subsequently enhances engine and system performance, as well as supporting overall packaging.

As just one element of our multi-faceted fabrication offering, any hydroformed products can be combined and integrated with our laser cutting, welding, machining, additive manufacture and insulating capabilities, meaning we can deliver a fully integrated, turnkey component to our customers.

To find out more about our wider fabrication capabilities, click here: How we make fabricated structures

Or if you have an enquiry as to how the HydroLite® process can enable your technologies, speak to our team here: Contact Us

A guide to our cutting-edge machining facilities

Thu, 23 Jan 2025 08:08:44 GMT

We utilise our extensive and capable machine shop to support and enhance our manufacturing processes.

Our machining facilities are used to create components or tooling within the construction of a product assembly. This ensures that we are able to provide complex, quality products for customers in a variety of high-performance markets.

Machining is used at all stages of the product cycle, from pattern machining for composite moulds and tooling through to precision finishing of final components. Having this capability in-house, and at our Bicester site, eliminates any potential sub-contracting issues or delays and facilitates fast-make, high-volume production.

The following are selected examples of our machines and their capabilities:

Mazak Vari-Axis i600:

· Simultaneous 5 axis CNC machining centre

· Maximum part diameter of 600mm x 600mm x 600mm

· MSP software installed to optimise fixturing and part-setting

· Works with range of different metals

· Can be integrated with additive manufacturing products

SAHOS 5 Axis:

· Simultaneous 5 axis vertical machine

· Maximum part diameter of 3000 x 1500 x 800

· Spindle with a maximum of 20,000 rpm

· Works with range of different composite materials

Our machining capabilities also include 6 axis precision laser cutting, solid-state laser welding, twin-spindle turning and Direct Metal Laser Sintering (DMLS) 3D printing facilities.

To find out more about our capabilities, and to submit an enquiry to our team, please click here: https://www.polartechnology.co.uk/contact

Polar Technology implementing brand-new filament winding machine to enhance high-volume manufacturing

Tue, 10 Dec 2024 08:41:36 GMT

We have recently installed a brand-new filament winding machine as part of a designated, world-class manufacturing cell

This new investment is designed to increase and improve our volume production filament winding capabilities as we continue to support a varied, high-end customer base.

The new equipment is a dual mode, 3 spindle, 9 tow machine capable of winding components of varying sizes at high speeds, from small magnet rotor sleeves for advanced electric motors to 5m long hydrogen storage tanks.

This is just one element of a larger, dedicated cell, which will also include other advanced machinery, facilitating a comprehensive, streamlined and strictly quality-controlled process. This will ensure that we are maximising reliability, repeatability and productivity in the products they provide their customers.

As a leading provider of filament wound products, the new facilities will only serve to complement the existing winding capabilities at our 180,000 sq ft site, with our current product portfolio including, but by no means limited to, high-volume production of transmission shafts , pressure vessels and magnetic rotor retention sleeves .

The new facility will be used to support existing customers, fulfilling current contracts with capacity and capability to support further planned expansion and growth.

Edward Keating, Technical Project Manager at Polar Technology, who has overseen the implementation of the machine, said, “This investment in new equipment is a reflection of Polar’s unwavering commitment to support its customers in the drive to achieve Net Zero by 2030, and to explore new opportunities in growing markets. The new filament winding machine will support higher-volume manufacturing going forwards and increase our overall winding capabilities. It’s a project we’re all very excited about.”

If you have an enquiry regarding our filament wound capabilities, please contact our team now: Contact Us

How we make pressure vessels

Wed, 20 Nov 2024 16:02:57 GMT

We are specialists in the design, development and manufacture of composite pressure vessels for the storage and transport of fluids and gases at high pressures.

Our vessels function as enabling technologies in a variety of high-performance industries, with our market-leading weight efficiency enhancing fuel efficiency, increasing payload capacity and optimising utilisation of space.

We currently have capability to design and produce pressure vessels of two types of construction:

· Type 3 - Aluminium liner with composite overwrap

· Type 4- Polymer liner with composite overwrap

The following is a step-by-step guide to the process we use in creating them:

1. Detailed Design

The process begins with one of our skilled engineers receiving a brief from a customer and creating a design, based on the required specifications, operating pressure and geometry.

It is at this point that the type of liner is selected, based on the specifications given and always with the aim of achieving the maximum weight-efficiency for the end application.

2. Manufacturing of Liners

We are able to manufacture liners using a variety of methods. For the Type 3 liner, we utilise a combination of machining, welding, spin forming and flow forming, depending on the geometry and requirements

For Type 4 liners, we employ a method called roto moulding, which involves using a hollow mould, filling it with plastic material and then rotating and heating it at a high temperature, until it melts and coats the inside of the mould, replicating its shape.

3. Additional Special Processes

After the liners are manufactured, they are then subjected to additional special processes, such as coating. The purpose of this is to alter or enhance the material, often to better protect the vessel against potential corrosion.

4. Filament Winding

Just as in the creation of our transmission shafts , the key process in the development of pressure vessels is filament winding, a specialist technique where layers of carbon fibre are continually wrapped around the liner as it is rotated.

The benefits of using this method for pressure vessels are that it allows for optimised fibre placement to better resist internal pressures. This makes this technique a popular option for vessel applications in the automotive and aerospace industries.

5. Painting

If the customer requires a specific visual appearance, our in-house paint shop enables us to provide a variety of painted finishes and coatings to the vessel.

6. Non-destructive testing

There are three stages of testing that we employ to ensure that our vessels are always compliant. The first is proof testing, which is a process in which the vessel is subjected to pressure, in order to test its integrity. In the case of type 3 liners, we employ a method called autofrettage.

The second is leak testing, where we use pressure to identify any defects or leaks in the product. And finally, dimensional inspection allows us to ensure the geometry is fully conforming to the specification.

And that’s how we create pressure vessels that are fully integrated solutions, ready to be implemented immediately into our customer’s technologies. For more information on our capabilities, please click here: Our Products | Accumulators and Pressure Vessels

Finally, the techniques we employ for traditional pressure vessels are also applicable to the storage of hydrogen. For more information on this new area of development, please click here: https://www.polartechnology.co.uk/polar-technology-developing-innovative-solutions-for-hydrogen-storage

If you have an enquiry regarding a project that requires expertise in pressure vessels, please contact our team here: https://www.polartechnology.co.uk/contact

A guide to our specialist, high-performance moulded department

Wed, 06 Nov 2024 15:28:44 GMT

Our skilled team can support with a variety of complex, high-volume projects.

For all further information on our capabilities and previous experience, please see the interactive brochure below:

To get in touch about your moulded composite requirements, please submit an enquiry to our team here: Contact Us

A Day in the Life of a Development Engineer

Mon, 21 Oct 2024 13:15:48 GMT

Ben, one of our Development Engineers, takes us through his typical day at Polar Technology.

Ben gave us an insight into what a typical day for him is like: "To be honest, in my role, no day is the same! There is a lot of variation, which is a great thing. I'm always encouraged to get involved in the projects that I'm interested in. For example, I'm a huge fan of motorsport and one of my first projects at the company was to work on the design and development of carbon rotor sleeves for a major Formula One manufacturer."

"The best bit of my job is that I feel like I have a direct impact on the business. I was given so much responsibility and trust pretty much straight away. Alongside that, it really does feel like you're part of a team, all working towards the same collective goal. Whenever I am stuck, I feel like I can ask literally any of my colleagues for help and someone will go out of their way to help me. There is fantastic camaraderie in the office!"

"Another major incentive was our state-of-the-facilities and the location. Being so close to Oxford offers me flexibility and a great work-life balance, and pulling into a site that's as impressive and modern as ours everyday doesn't hurt either!"

If you're interested in finding out more about what it's like to work for Polar Technology, and the current vacancies we have available, please visit our Careers page: Careers | Ambitious Innovation Takes Brilliant People (polartechnology.co.uk)

How we make fabricated structures

Tue, 15 Oct 2024 07:06:36 GMT

A step-by-step guide to the process we follow in creating bespoke, advanced fabricated structures.

Metal fabrication is one of the key areas of expertise we possess here at Polar Technology, with our fabricated structures serving as exhaust systems in prominent vehicles in the motorsport and automotive industries, safety critical structures suitable for weapon mounting and fluid conveyance systems within an aircraft.

Fabrication is a process that uses raw, unfinished materials to construct a larger, complete component or structure, often using techniques such as welding, cutting and bending. The benefits of the process are that it is a reliable, repeatable method of developing strong, versatile components, making it perfect for the demands of high-performance industries.

We are able to offer customers constant engineering support throughout the design and development of a product, processes that are audited to industry standards such as AS9100:REVD and ISO9001, and the guarantee of qualified and experienced coded welders.

The following is a step-by-step guide to the process we follow in creating bespoke, advanced fabricated structures:

1. Tube Bending

The process begins in our tube-bending department, where we utilise our CNC bending machines to reshape tubes from their original straight form. Normally, the component will start out as thin sheets of metal, such as Inconel, stainless steel and aluminium, before it is curved into the shape required.

2. Kitting

Along with the tubes, we manufacture all other components required for the assembly, which are kitted and checked before starting fabrication. We also create fixtures and jigs by using our in-house machining and laser cutting facilities. This means that all the required elements are delivered in one complete kit, ready to be manufactured together by the fabricator.

3. Fabrication

Our skilled fabricators operate in designated ‘cells’, fitted with all the tooling required for a range of fabrication processes. Often the various elements may need to be reconfigured slightly, so this is where techniques like grinding and dressing are utilised.

4. Welding

Welding involves combining two separate metal pieces together using heat. This is mainly done using a TIG (Tungsten inert gas) welding method, although MIG (Metal inert gas) is also used specifically for larger applications, The jigs are used to accurately locate each section of the assembly together to help ensure the final part is geometrically correct.

5. Assembly

Once the welding is completed, there will be a singular, finished component. In some cases, this could be the end of the process, as other than tidying and polishing up the structure, it is ready to be fitted into the customer’s technology. However, we offer additional services to ensure we are providing a high-quality, turnkey solution to our customers.

6. Non-Destructive Testing

Our in-house Non-Destructive Testing (NDT) facilities allow us to inspect and validate our fabricated structures and check for any defects. A common technique we use is liquid penetrant testing, where a liquid is sprayed over the component and then cleaned, to expose any cracks where the penetrant has seeped into. We also use our Romer Arm inspection machine to test for geometric compliance.

7. Insulating

We can then insulate the component to significantly reduce heat transfer to the surrounding areas, which is crucial for high temperature applications. The process is done in three stages: applying lagging to the component to hold the heat in and securing with tape, covering with metal skins to build up the insulation and then heat treating the entire component to remove the tape.

Integration with Additive Manufacturing

Whilst not a step in itself, around half of our fabricated structures have components that are made in our additive manufacturing department. The benefits of using additive manufacturing is the ability to more easily create components with more complex geometry, and we are able to combine and integrate both processes within the production of a structure. You can find out more about our AM process here: How we build and integrate additive manufacturing products (polartechnology.co.uk)

To find out more about our fabrication capabilities, please click here: Capabilities (sstubetechnology.com)

Or to speak to our commercial team about an enquiry, please click here: Contact Us (polartechnology.co.uk)

Polar Technology developing composite retention sleeves to support the electrification of the transport sector

Mon, 07 Oct 2024 12:36:45 GMT

We have developed high-speed optimised Carbon Fibre Reinforced Polymer (CFRP) sleeves for use in electric rotor applications

Electric rotors have become a crucial component in the move to electrification within the transport sector, intensified by fast-approaching Net Zero deadlines. The challenges faced in the application of the rotors include the amount of centrifugal force generated at such high speeds, which makes it difficult to keep the magnets in place, and the subsequent current losses, which reduce the overall efficiency of the machine.

Polar Technology Management Group, an engineering and manufacturing business based in Oxfordshire, utilised their significant expertise in composite technology to develop high-speed optimised Carbon Fibre Reinforced Polymer (CFRP) sleeves for use in electric rotor applications. They have been chosen as the supplier for a number of different high-performance vehicle Original Equipment Manufacturers (OEM’s) and are currently producing thousands of sleeves for respective contracts.

The benefits of using CFRP as the sleeve material are its superior strength and tensile properties, allowing for a lightweight solution that still ensures retention of the magnets and that resists the centrifugal forces in high-speed applications. Specifically, the sleeves enable rotors to operate at speeds upwards of 30,000 RPM, whilst minimising current eddy losses and system air gaps.

Polar Technology assumes the design authority for the CFRP sleeve, taking the customer rotor specification, selecting materials, and then developing a design which meets the criteria and is proven through analysis and testing.

For the manufacturing process, Polar Technology employs its market-leading filament winding facilities to create the sleeves and worked with their customers to test and perfect a press-fitting technique to fit the sleeves to the rotors. The benefit of this process is a higher retention pressure compared to sleeves that are wound directly onto the rotor, which generates a higher power output for the final product.

Daniel Chilcott, Business Development Director at Polar Technology, said: “Continued increased performance and efficiency in electrical machines is an emerging trend and something our composite sleeve technology is directly supporting. We are delighted to see our customers scale and continue to push the envelope”

Polar Technology will be showcasing its innovative rotor sleeves during Advanced Engineering, taking place at the NEC, Birmingham on the 30 ^th and 31 ^st October 2024.

For more information on our composite retention sleeves, please click here: Composite Retention Sleeves (lentuscomposites.co.uk)

Or to speak to our commercial team about a potential enquiry, click here: Contact Us (polartechnology.co.uk)

How we build and integrate additive manufacturing products

Tue, 17 Sep 2024 07:15:49 GMT

A comprehensive guide to the steps involved in the process of producing high-quality additive products for use in demanding, high-performance applications.

Additive manufacturing continues to be an area of rapid growth and innovation within the engineering and manufacturing sector. The process saves time and money and minimises waste, whilst it allows for easier prototyping and adjustments ahead of mass production.

Furthermore, our facilities here at Polar Technology means that we are able to offer customers far more than just high-volume production of printed products; we can integrate those parts into wider assemblies or more complex components, combining our additive manufacturing expertise with our extensive machining and fabrication capabilities.

The following is a comprehensive guide to the steps involved in the process of producing high-quality additive products for use in demanding, high-performance applications:

Step 1- Design and Build

The process begins with one of our engineers creating an initial design based on the customer’s brief. They then collaborate with our additive manufacturing department to translate that design into a manufacturable component using CAD (Computer-aided design) software, which involves choosing the right orientation and adding in support structures to ensure the integrity of the product is maintained.

This build process prioritises maintaining the geometric shape of the component, minimalizing material usage when possible and reducing the potential of distortion. The software that our AM team employs also allows for accurate forecasting of lead times and amount of material required.

Step 2- Machine Preparation

It is then time to prepare the printing machine. The first step is to clean all existing powder from the chamber and then the machine is run in an ‘inert’ atmosphere, which ensures that the chemical composition remains stable during the printing stage. Skipping this step could lead to higher levels of oxygen being present, which can lead to the finished components becoming brittle.

Step 3- Printing

The printing process works by a laser continually sintering the shape of the part onto layer after layer of material. Each time the laser has finished sintering one layer, a re-coater spreads another sheet of powder on top and the step repeats, allowing for the part to be built up one layer at a time.

This process allows us to create complex shapes with wall sections down to 0.5mm, typically half the thickness of a component created using traditional casting methods.

Step 4- Cleaning

As the fully printed part is retrieved from the machine, any excess powder is removed. The component is then placed in an airline cabinet, which is a high-pressure system that cleans it more thoroughly, to ensure there is no excess material present.

Step 5- Heat Treatment

The component will then be placed in a furnace, where there is a controlled ramp-up to a certain temperature, normally about 1000⁰c. This process makes the parts more ductile and significantly improves their durability.

Step 6- Wiring

After being cooled and removed from the furnace, the component will be taken to our Wire EDM (Electrical Discharge Machining) machine. Both the component and an electrically conductive wire are submerged in a dielectric fluid. This creates a sparking between the wire and the surface of the component, which allows for the precise cutting and removal of material.

Step 7- Finishing

There are various different stages that could be involved in the finishing of a product, dependent on the customer’s specific requirements. Often the support structures will need to be manually removed by one of our skilled operators. We also have a designated welding cell where the surfaces can be grinded down, for a smoother finish.

Finally, we also have a sandblasting machine, which efficiently removes any final grit, to leave a polished, complete component, ready for integration.

Step 8- Integration

For most typical additive manufacturing bureaus, this is where the process would end, with the printed product then being sent to customers.

However, we are able to add further value in the process, through utilising our sophisticated machining facilities or fabrication techniques to combine and integrate our AM components with conventional fabricated parts. For an example of this, click here: https://www.polartechnology.co.uk/polar-technologys-machining-solutions-supporting-production-of-3d-printed-products

Furthermore, we also have extensive inspection capabilities, which enables us to test our products and facilities throughout the entire build process. This breadth of knowledge within the organisation has allowed us to continually come up with innovative and bespoke solutions for our customers.

To find out more about our full AM capabilities, click here: https://www.sstubetechnology.com/capabilities

Or if you have an enquiry about a potential product or solution, please get in touch with our team by clicking here: https://www.polartechnology.co.uk/contact

Polar Technology’s machining solutions supporting production of 3D printed products

Wed, 11 Sep 2024 15:20:24 GMT

Through utilising solutions from MSP, our machining capabilities have gone from strength to strength.

Two years on from the implementation of CNC manufacturing solutions from leading metrology provider MSP, the production of 3D printed products at Polar Technology continues to be one of our success stories.

In early 2022, we enlisted MSP’s support to increase productivity, reduce setup time and halve the machining cycle. The initial challenge had stemmed from the nature of additive manufacturing, with distortion often occurring within the build process and therefore requiring finish machining on a CNC machine to bring the part into tolerance. This is difficult however, as a precise alignment is needed to cut the part accurately, something which is hard to achieve when it is unknown how the part has changed in the build process.

The solution was to install MSP’s NC-PartLocator on our Mazak Variaxis i-600 CNC Machine. This automates the part setup process by calculating precise alignments for each machining operation, removing the need for any manual alignment and multiple machining steps. The software presents the machine operator with detailed graphic information at every stage of the process to ensure accuracy throughout.

We also utilised MSP’s NC-Checker, which produces automatic reports on the performance and accuracy of the machine tool, before any machining begins, which is crucial to ensure no machine errors will ripple down to the final additive parts.

The Variaxis i-600 offers 5-axis capability, enabling high-accuracy, high-speed machining of multiple surfaces. This machine, coupled with MSP’s software, has transformed our production of 3D printed products, leading to huge improvements in reliability, efficiency and consistency.

Thomas Rogers, Machine Shop Manager, said: “The knowledge we have gained over the past few years has helped us understand the challenges of machining additive products. We utilise the MSP software to optimise fixturing and part-setting. This has led to new and exciting projects for the business, including creating high-precision, intricate development parts for an aerospace supplier that were chosen over parts produced by their approved R&D lab.

“Our reliable and high-quality machining solution, along with inhouse additive manufacturing and fabrication departments, can offer a complete and robust product from design inception to final production.”

Aidan Wigham, MSP Technical Account Manager said: “At MSP it's our goal to enable our customers to achieve right-first-time production of high value and complex parts. It's impressive to see the results being realised by Polar Technology - their drive for innovation makes for an exciting partnership.”

For more information on our full machining capabilities, please click here: Capabilities (sstubetechnology.com)

For more information on MSP’s products, click here: Metrology for the CNC Manufacturing Industry (mspltd.com)

Our Solutions for the Aerospace Industry

Mon, 19 Aug 2024 07:26:17 GMT

In honour of National Aviation Day, we're celebrating the innovation at the core of our aerospace offering.

Polar Technology have supplied our products and services on many of the major aerospace programmes delivered in the last ten years. Our innovative and enabling solutions address many of the global challenges that the industry faces, including saving fuel, reducing emissions and improving durability.

We can offer constant engineering support, the most advanced manufacturing technology and strict quality systems that ensure the highest standards are always maintained.

This means that whatever the demands, we are perfectly positioned to deliver a novel, high performance solution. The following is just a sample of our full product portfolio:

Transmission Shafts:

We are market leaders in producing specialist composite transmission shafts, suitable for integration within an aircraft engine or actuation systems.

We have developed a patented composite to metallic mechanical interface, which removes reliance on adhesives that can be prone to fatigue and premature failure. Our shafts can subsequently deliver high speeds and high torques with infinite durability, whilst still remaining a lightweight solution.

Our in-house processes are flexible, depending upon the specifications of the product required, and can be adjusted to suit low or high-volume production.

Hydrogen Storage Solutions:

Hydrogen storage is of growing significance within the aviation industry, with many viewing it as a potential solution in the challenge to reduce carbon impact.

Leveraging expertise in lightweight, composite high-pressure cylinders and hydraulic accumulators, and in the area of cryogenic liquified gas storage down to liquid helium temperatures, we have developed innovative solutions for gaseous storage and we’re working on liquid H2 storage.

These solutions have been focused on three main areas:

· Extremely light weight cylinders offering industry-leading gravimetric efficiency.

· The novel ‘Hydrogen in a Box’ which increases volumetric efficiency by 25%.

· Technologies for the cryogenic storage of liquified H2.

Safety Critical Structures:

As experts in the welding and fabrication of tubular structures, we develop complex aluminium, titanium and stainless-steel frames, suitable for weapon equipment mounting, and UAV structures.

Our in-house capabilities mean we are able to manage all stages of the manufacturing process, from tube manipulation to heat treatment and even non-destructive testing. Structures manufactured from metallic and composite materials are often finished using our CNC machines, delivering high accuracy, performance and longevity.

We utilise materials and employ processes that are resistant to highly corrosive environments, making them ideally suited for integration within a safety-critical system.

Lightweight Bladed Fans:

Net zero flight, advanced propulsion and high load fluid transfer all rely on bladed impellors, fan and propellers. We have experience developing lightweight, co-cured bladed fans to meet demanding specifications.

Our blades are built from carbon fibre pre-impregnated with epoxy and manufactured in a multi-element strategy that delivers a fully integrated, class-leading solution, whilst our specialist working knowledge of trapped and complex tool solutions allows us to tackle complex designs.

Through our partnerships within the industry, we are able to offer the incorporation of a novel method for applying ‘leading edge’ erosion protection layer, improving the ability of composite materials to withstand the thermal and erosion requirements of the most demanding environmental conditions.

To find out more about our full range of products and their aerospace applications, go to our Products page: Products (polartechnology.co.uk)

Or to speak with a member of our commercial team about your specific requirements, please click here: Contact (polartechnology.co.uk)

Polar Technology supporting The Hummingbird Centre as charity of choice for 2024

Mon, 12 Aug 2024 08:00:02 GMT

We will be raising money for the cancer support and therapy centre in Bicester.

Each year, Polar Technology employees vote to select a local charity for the company to support, through raising money at various fundraising events. For 2024, the chosen charity is The Hummingbird Centre, a cancer support and therapy centre in Bicester.

The Hummingbird’s goal is to relieve the mental and physical sickness of people suffering with cancer and to offer support services to both them and their loved ones. The centre is a place where it’s guests can feel warmth and support, learn and feel as happy as is possible during their cancer journey.

One of the reasons that Polar Technology employees chose The Hummingbird was the range of services that the centre is able to offer its guests. They include:

- Play sessions and group counselling for children aged 4+ who are either suffering with cancer themselves or seeing a loved one go through the journey.

- Meditation and hypnotherapy to help with the mental stresses of cancer.

- Variety of arts and crafts sessions for guests to have fun and chat with people who are going through similar experiences.

- Workshops that give valuable, practical tips for improving sleep and getting better nutrition.

- Complementary therapies, such as sound therapy and Reiki, that offer valuable relaxation and relief from pain.

- Sessions with trained counsellors to support at all stages of the cancer journey.

Tracy Dewhirst, Marketing Manager for Polar Technology and Chair of the Social Committee, explained the decision to choose The Hummingbird: “When it came to choosing our charity for this year, we wanted to make sure we were supporting a good cause within the local community. By choosing a smaller charity, we knew that we would be able to directly see the difference our donations were making. We’re delighted to be supporting such a worthwhile cause!”

Mechelle Harris, Founder of The Hummingbird Centre, added: “We are so pleased to have Polar Technology supporting us. I found it truly humbling to know it’s the employees that have voted for us, as you never know how and why a company decide to support you. It’s important to us that Polar Technology feel part of the charity and become involved during their time with us, there are exciting times ahead”.

The Hummingbird is not just looking for donations, but also volunteers who can help out the guests at the centre. They are especially interested in hearing from anyone with skills in arts and crafts, or who can provide some of the therapies offered. To find out how you can support them or get in touch, click here: How Can You Help? | Hummingbird Centre (thehummingbirdcentre.org.uk)

Health and Safety Committee Relaunched

Wed, 07 Aug 2024 12:45:00 GMT

Polar Technology have recently relaunched their Health and Safety Committee.

The committee is made up of representatives from across the company and will meet once a month to discuss all health and safety matters.

The purpose of the monthly meetings is to provide a forum for feedback and open discussion, to represent all employees by having a representative from each area of the business and to share progress on actions and improvement projects.

The inaugural meeting took place in July, and covered topics including dust extraction, noise improvements and new information signs for all doors. The committee are also assisting the QESH (Quality, Environment, Safety and Health) Team with a revised Health and Safety policy.

This relaunch is a further example of our continued commitment to providing the safest and most efficient workplace that we can for all our employees and ensuring the highest operating standards for our customers.

Polar Technology celebrate Cycle to Work Day

Tue, 06 Aug 2024 13:15:55 GMT

To mark the occasion, we were offering an incentive for the person who cycled the furthest distance, and a bacon sandwich and hot drink for everyone who had a go!

Last week, Polar Technology celebrated Cycle to Work Day. The point of the day is to encourage anyone to get in the saddle and experience the brilliant mental and physical benefits that everyday cycling offers.

Our participants all provided the details of their journey, as well as their cycling experience:

Scott Roberts, Co-Founder, said: “I cycled in from Denchworth, which is near Wantage, and back. I picked up Jake at Southmoor on the way in, which made it a 33 mile round trip. I normally cycle in two days a week, up the Ridgeway, on my Specialised Stump Jumper mountain-bike.”

Michelle Lewis, QESH Manager, said: “I cycled 35 miles in total, going a slightly different route home to avoid a busy stretch of road. I have a Trek Emonda ALR 4 Disc road bike in red and orange, which I love! I am a bit of a fair weather cyclist in general, though earlier this year I completed the Ride London-Essex 100.”

Lochlan Gunn, Manufacturing Development Engineer, said: “I completed my normal commute of around 12km from my home in Oxford and back, on my Colnago Titanio CT1 road bike, though unfortunately I got a puncture around the 8km mark on the day!”

Jake Longman, Paint Shop Manager, said: “As Scott said, he met me by my home in Southmoor, near Abingdon and then we completed the rest of the journey together, which is about 12 miles, and then the same on the return leg.”

The winner of the competition was our Laser Technician, Jay Hewlett , who clocked up an impressive 51 miles on the day, starting in Cowley in Oxford but taking a much longer scenic route on the way home to secure victory!

Jay explained: “I did extra on the way home as it was such a nice evening, which was another 40 miles; I must admit I did get a bit lost! The reason I pushed for that is I wanted to hit my first 50 miles in a day.”

“I rode my new electric bike which is pedal assist only, so you can’t just cruise along, you still have to put the work in! I also called electric bikes cheating until I got one; it only has a 25-mile range at the most, so you can’t just ride with the power on all the time, you have to pick your moments.”

To further encourage cycling on a day-to-day basis, Polar Technology offer a Cycle to Work Scheme, to help colleagues spread the cost and save money on bike and safety equipment through salary sacrifice. More information can be found on our People page: People (polartechnology.co.uk)

Polar Technology and Ultima Forma collaborating on erosion protection solution for aerospace applications.

Thu, 25 Jul 2024 08:30:00 GMT

Ultima Forma and Polar Technology are collaborating to expand the adoption of carbon fibre composite (CFRP) materials for aerospace applications.

By combining their technologies, they will achieve improvements in the ability of CFRP 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.

An electro-deposited erosion protection layer, as developed by Ultima Forma, can be carefully controlled, readily adapted to different designs, and importantly, scaled through automation as the volumes of propeller blades increase, e.g. with the UK's new eVTOL entrants.

Ultima Forma's patented material systems are tailored to meet the environmental challenges of different components. These include functionally graded, resilient, thickness-controlled metals at different locations made by an automated manufacture process. Only the electro-deposited metal is required, minimising weight and mass distribution. The metallization process is a low energy, zero waste, net-shape manufacture, operating close to room temperature, minimising the carbon footprint of both the manufacture processes and the product.

Polar Technology, Oxfordshire-based specialists in composite and metallic technology, will be producing the aerofoil-shaped composite components, which the erosion protection layer will be applied to. This project is reflective of the company’s current strategy, with more than 10,000 eVTOL aircraft deliveries expected to be made by 2040, each reliant on several multi blade rotor assemblies for propulsion. This means that the blade and propeller market is a key focus for Polar Technology’s engineering team.

James Bottoms, Engineering Manager for Composite Products, said: “Polar Technology consider electroformed coating of composites to be an enabling technology on our route to a sustainable and healthier future. The solution could provide the performance and safety advantage required to meet the demands of eVTOL flight among other applications in the aerospace sector. Working with our partner, Ultima Forma, we want to offer our customers the best technology for the protection composite rotor blades, improving product lifecycle, reducing operational waste and manufacturing cost as well as offering performance improvements over existing technologies.”

Andy Bushby, Chief Technology Officer at Ultima Forma, added: “At Ultima Forma, we want to use our materials science and electroforming technology to deliver lightweight leading edge solutions, to ultimately enable more efficient hybrid systems.”

For more information on our composite rotor blades, click here: Composite Structures (lentuscomposites.co.uk)

Polar Technology supporting the development of Striker® II fighter-pilot helmet

Tue, 23 Jul 2024 07:50:08 GMT

Polar Technology awarded multi-year contract to support BAE Systems in the development of the Striker ^® II fighter-pilot helmet for the UK Royal Air Force.

In a strategic collaboration, Polar Technology Management Group will work with BAE Systems in a contract awarded by the UK Ministry of Defence, supporting in the development of the structural elements of the Striker ^® II Helmet-Mounted Display for the Royal Air Force’s Typhoon fleet. This fully digital solution is poised to revolutionise situational awareness for Royal Air Force Typhoon pilots, ensuring their safety in the ever evolving and contested airspace.

Developed at BAE Systems in Rochester, UK, the Striker II is one of the world’s most advanced fighter pilot helmets, which uses the latest technologies to integrate its all-digital night vision system and daylight-readable colour display. Striker II transforms the pilot's helmet visor into an augmented reality interface, overlaying mission-critical data onto the real-world environment.

Utilising the in-house expertise at their specialist, Oxfordshire-based site, Polar Technology supported BAE Systems in the design and development of the high integrity composite structure and 3D printed optics frame assembly. This is central to the functionality of the advanced capabilities of the Striker II, as it allows the cutting-edge optical sensors and associated software to function as intended throughout the product lifecycle.

Paul Janes, Managing Director at Polar Technology, said: “This collaboration represents a flagship programme for our team and we’re incredibly proud to be supporting BAE Systems’ efforts to ensure that the Striker's capabilities remain at the forefront of innovation.”

Nigel Kidd, director for helmet-mounted displays at BAE Systems in Rochester, said: “Striker II is a critical programme, set to provide Typhoon pilots who defend the nation and our allies with battle winning capabilities and enhanced safety. This collaboration will help us to deliver on our commitments to the UK RAF and continue to innovate for those who protect us.”

For more information on our composite expertise, click here: THEME - Lightweight Structures (polartechnology.co.uk)

How we build transmission shafts

Mon, 15 Jul 2024 13:25:51 GMT

A guide to producing lightweight, energy-efficient transmission components

The use of composite transmission shafts is increasing rapidly in the aerospace industry, as more and more businesses are attracted to the high durability and long fatigue life that they offer whilst remaining a lightweight solution.

Polar Technology are established leaders in the development of lightweight, energy-efficient transmission components, having supplied a variety of shaft assemblies to industries ranging from automotive and motorsport to rail and aerospace.

Our patented composite to metallic mechanical interface removes reliance on adhesives and enables a more durable shaft, capable of delivering the highest speeds and torques.

Our in-house processes are flexible, depending on the specifications of the product required, but all follow a similar, scalable method that ensures a high-performance solution every time:

Step 1- Winding

Filament winding is a specialist technique, which involves wrapping continuous fibres around a rotating mandrel.

Firstly, the fibres are unwound from spools and run through a series of rollers. They then pass through a resin bath that impregnates the material with an epoxy resin, before being wound onto the mandrel. Alternatively, components can also be wound with pre-impregnated material, which skips the resin bath stage.

The angle at which the fibres are wound onto the mandrel dictates the properties of the final product and defines the strength, stiffness and torsional resistance of the shaft.

Step 2- Curing

After the winding process, the composite material is placed in one of our ovens, where they are cured at specific temperatures and conditions. This process is what binds the composite elements to allow the transfer of loads through the fibres.

For the pre-impregnated components, they are cured in one of our autoclaves, which applies up to 150 psi of pressure, to compress and consolidate the composite material.

Step 3- Mandrel Removal and Slitting

For hollow tube structures, the mandrel is extracted from the composite tube and transferred to our machining department for slitting, where our operators will cut the tube to the specified length.

Step 4- Measuring

Our composite wound shafts are carefully inspected to ensure the length, outer and inner diameters meet the required specifications. At this point, the composite shafts will also undergo visual inspection and NDT (Non-Destructive Testing) to ensure that there are no defects which could compromise the structural integrity of the part.

Parts are also measured throughout the build cycle to ensure accuracy is maintained and inspection data is logged on our data capturing system.

Step 5- Pressing

Now the composite structure is ready to have the machined end fittings pressed onto it. Our machine is compatible with a wide variety of tooling to enable different fittings to be applied to the composite shaft.

This is where our patented mechanical interface is utilised, as the composite structure and metallic end fittings are combined solely by applying pressure at either end.

Once the fittings are attached, bearings can also be added for extra support, if the shaft requires it.

Step 6- Balancing

Shafts will then be taken to our balance machine, which is used to rotate the shafts at a given RPM to analyse any imbalance that may be present.

Any imbalance is then corrected by addition of material through spot welding, and this ensures that the weight distribution along the shaft is neutral and the rotating masses at either end are evenly distributed, thus minimising noise and vibration issues.

Step 7- Testing

The final stage is moving the shaft to our designated quality control area. Using our metrology and inspection facilities, which include CMM machines and portable CMM with laser scanning capabilities, we can check to ensure parts are conforming to the required specification.

Once all tests and inspection criteria for the assembly have passed, we carefully package and send the completed assembly to the customer, ready for integration within their own technologies.

And that is how we produce transmission shafts for a variety of high-performance applications. However, the experience we have in the process of creating wound composite structures is transferrable to all kinds of products for a wide range of industries.

We also use this method, or adaptations of it, to develop pressure vessels, hydraulic accumulators, composite rotors and more. If you want to find out more about our wound capabilities, click here: https://www.lentuscomposites.co.uk/capabilities

Or if you want to speak to our engineering team to better understand how we can assist your product development, then click here: Contact (polartechnology.co.uk)

Polar Technology and Intelligent Energy combine tech to deliver endurance system for UAVs

Thu, 04 Jul 2024 08:00:01 GMT

Innovative new system significantly increases UAV range

Attendees at this summer's Farnborough Airshow will be given a glimpse into the future of unmanned aerial vehicles (UAVs) as a result of an innovative partnership between Polar Technology and Intelligent Energy.

Polar Technology, an engineering business leading the way in the development of composite and metallic technologies to support the hydrogen economy, is debuting an innovative, high-performance hydrogen storage solution at the airshow.

The new cylinder achieves class-leading 7.5% weight efficiency and has a water volume of 14.4l, whilst operating at 350bar pressure. This is the result of a super-thin-wall liner, which pushes the boundaries of what is achievable with Type 3 technology. The new cylinder holds 25% more fuel without an increase in weight, with dramatic implications for UAV range and performance.

To demonstrate the impact the new cylinder can have, Polar Technology has teamed up with leading hydrogen fuel cell manufacturer Intelligent Energy.

Combined with Intelligent Energy’s hydrogen fuel cell, the new cylinder will allow UAVs to triple their range. Not only that, hydrogen fuel cells emit no CO2 compared to IC engine alternatives and generate less vibrations and noise, meaning UAVs with the new system are cleaner and longer lasting than the alternatives.

These fuel cell powered UAVs have applications across numerous industries from energy, they are used for surveying power lines and offshore wind infrastructure, to logistics and delivery services. The increased range and flight time of the Polar Technology and Intelligent Energy system could replace boats, helicopters and other vehicles that are far more expensive and carbon intensive.

During the manufacture of the new cylinder, Polar Technology validated the cylinder design through Finite Element Analysis (FEA). The findings that followed this analysis are now being fed back into Polar Technology’s broader processes to ensure there is correlation between the theory, FEA, and physical testing.

Commenting, Daniel Chilcott, Business Development Director at Polar Technology, said: “We have been working very closely with Intelligent Energy over the past 18 months. Intelligent Energy’s leading-edge fuel cell solution for the UAV market combined with our class leading lightweight cylinders takes the end user experience to another level.

“Users can begin operating UAVs in whole new ways, opening up new markets and applications. I’m excited to see continued progress which will be boosted further as the legislation for visual line of sight (BVLOS) relaxes in the near future.”

Commenting, Andy Kelly, Head of Product at Intelligent Energy said: “The combination of our fuel cell technology and Polar Technology’s light-weight cylinder further distinguishes fuel cells as a power system of choice in the UAV market. Compared to alternative technologies this system is cleaner, longer-lasting and with a dramatically increased range that makes new applications possible .

“It’s been great working with the team at Polar Technology and we look forward to seeing our UAV on display at Farnborough.”

For more information on our hydrogen storage solutions, click here: Hydraulic Accumulators & Pressure Vessels (lentuscomposites.co.uk)

How moulded composite products are made

Wed, 26 Jun 2024 13:27:39 GMT

A comprehensive guide to developing high-performance composite products.

One of the key areas of expertise we have here at Polar Technology is in the development of moulded composite products. We have utilised this method to create a wide spectrum of composite structures and components, including class-A surface components for hyper cars, the bike frames for Team GB at the 2016 Rio Olympics and bladed fans for aerospace propellers.

So, how does the process of creating moulded products work? We’ve leaned on the experience of our specialist team to create a comprehensive guide, taking you through each stage, to understand how we develop high-performance products from raw composite materials.

What materials do we use?

Going right back to the start means looking at the composite material itself, and the most common material we use is carbon fibre. To create carbon fibre, strands of material are heated to high temperatures and exposed to various chemicals. Next, they are woven into normal fabric, just like in the textile industry.

After it’s been woven, it goes through an impregnation process where a special kind of resin is added, which gives the carbon fibre a particular weight, this resin can be partially cured or “B-staged” to form the resin impregnated material commonly known as pre-preg. These rolls of material are then stored in freezers, ready to be defrosted whenever we need them.

Step 1- Cutting

As required, the rolls of carbon fibre pre-preg will be defrosted overnight and then the next day, they will be cut into kit form. Using our CNC machining centres, we can create clean and precise patterns without any damage or distortion to the material. Once cut, they will be given to one of our skilled laminators.

Step 2- Laminating

Each of our laminators will follow an exact drawing or lay-up manual when producing a component. Using specialist hand tools, they will place the pre-cut forms or cut the material to match the specifications and then arrange it within a designated mould. The component is made up of lots of different layers of the carbon fibre pre-preg, for maximum structural integrity.

Step 3- Vacuum Bags

Once the laminating is finished, the component will be covered in a release film and then a breather cloth before being placed inside a vacuum bag.

The release film ensures the carbon fibre doesn’t stick to the breather cloth, whilst the breather allows the air to be extracted from the laminate and the vacuum bag.

Step 4- Curing

Once the component has been in the vacuum bag, it is ready to be cured in one of our autoclaves. Our autoclaves have a maximum pressure of 150 PS and a maximum temperature of 200 degrees Celsius.

Over a period of time, the pressure of the autoclave will compress the component (which is still inside the vacuum bag) and that consolidates the multiple layers of carbon fibre.

Step 5- Demoulding and Quality Control

From the autoclaves, the component will be returned to the laminator to be removed from its mould. Our quality inspector will then check the component against the required dimensions, to ensure it is compliant, before it goes through any finishing processes.

Step 6- Trimming

Next, the component will be finely trimmed, which means that any excess material will be removed, and its surfaces will be smoothed.

At this point in the process, there are two options available: the component will either be trimmed by hand in our trim shop or will go to one of our machining centres for a more precise finish.

Step 7- Machining

The reasons we utilise machining is because some parts require greater precision, which only our CNC machines can deliver. We use vacuum fixtures, which holds the component in a free-form position, and then we machine any holes, shapes or patterns that the design requires.

Step 8- Assembly

The component is then ready to go to assembly. We offer our customers mechanical and electrical assembly, as well as full supply chain management and lineside and kanban delivery.

That means that it leaves our site as an entirely finished product and goes straight to our customers, ready for immediate integration into their own technologies.

Step 9- Paint Shop

Some of our customers prefer a high-spec finish to their components, which is where our specialist, in-house paint shop comes in. We can apply lots of different kind of finishes, including coloured, clear coat and satin. This enhances the aesthetics of the component and ensures it comes out looking as impressive as possible!

And there you have it, an overview of how we produce composite products, using autoclave cure, pre-preg moulding techniques. If you want to find out more about our composite capabilities, click here: Capabilities (lentuscomposites.co.uk)

Or, if you want some advice or support on your moulded composite requirements, click here to speak to a member of our team: Contact (polartechnology.co.uk)

International Women in Engineering Day

Wed, 19 Jun 2024 13:57:00 GMT

Hear from our female colleagues on their experiences

Despite the significant process made in the previous few years, it is estimated that only 16.5% of engineers in the UK are female, with a similarly low percentage for other roles within the wider engineering and manufacturing industries.

International Women in Engineering Day, which takes place on the 23 ^rd June this year, has become a platform to shine a spotlight on the women who are acting as trailblazers within the industry and inspiring future generations.

At Polar Technology, we recognise the issues of representation within the industries we operate in, and we have made significant progress in increasing our percentage of female employees, but we know there is still more we can do. To find out more about the experience of women within our workplace, we spoke with a number of our female colleagues to hear what they had to say:

Kay Bicker, Composite Technician

“I’ve been at Polar Technology for six years, and I’ve seen a big increase in the number of women working here over that period. That has definitely changed the dynamic slightly within the moulded composite department, as we’ve moved away from an almost completely male environment.”

“My favourite part of my job is being able to take a product right the way through a process, from start to finish. That means that if I see a car at a show, I can have the satisfaction of knowing that I built a part of that.”

“I think the problem [of representation] is that industries like engineering and manufacturing are still gendered somewhat, and that starts at school. However, I think the increase in different kinds of opportunities, like apprenticeships for example, have given young girls another route in.”

Rosie Wilson, Trainee Quality Engineer

“In my previous role, I worked in a manufacturing company in Swindon, where I was one of only two women on the entire factory floor. That can be quite daunting and sometimes your abilities and understanding are questioned, so there was definitely a sense of having to prove yourself.”

“I’m pleased to say that’s not been the case at Polar Technology, where instead it feels as if everyone is expected to arrive at the same level, regardless of whether you’re a man or a woman.”

“I think the issue is the lack of representation. Engineering was not an option that was advertised to me. However, the more women that get into the industry, the more it will be seen as an option for everyone. So, if you can’t see another woman doing the job you want, be the first to do it!”

Melody Leung, Quality Engineer

“I think the first thing to say is that this is not just a UK issue, it’s a global problem. I’m from Hong Kong and there were the same prejudices there. Whilst things are definitely improving and ultimately, we are being treated the same as the men, I think it takes more dedication for a woman to get to that point.”

“So, whilst it’s good that we are getting the same opportunities now, a woman might have to do a bit more than a male counterpart in order to prove her worth.”

Iwona Opalczewska, Health and Safety Administrator

“Before my role at Polar Technology, I worked in the construction industry for twelve years and I was the only woman. It was fine when I worked for my husband’s company, but then when I changed jobs, it became a massive challenge. Sometimes it felt that my male colleagues didn’t listen to me or respect my opinion.”

“That’s not been the case at Polar Technology thankfully and in our office in particular, there’s much more of an even split between men and women. I think what helps is that I’m not very ‘girly’, so it doesn’t really bother me being in a typically male-dominated environment. You get used to it over time!”

“The best part of my job is seeing the benefits of the changes you implement. People come and see me and tell me that a new policy is working or that their concerns are now being heard and acted on, and that’s very rewarding.”

“My advice to young women who might be considering a career in this industry is: Just go and do it. If you enjoy what you are doing, then there is nothing that should stop you.”

Sharon Barrett, HR Director at Polar Technology, added: “Having a more diverse workforce provides us with a greater range of talent, offering different ways of thinking, better problem solving and more creativity. Whilst diversity is not simply about gender, we did feel this was a real gap for us because the reality is we work in a sector where there is a clear gender imbalance. It has been important for us to develop an offering that is attractive to women and girls and dispel the outdated image that engineering is dull and boring.”

This has led to a big focus on diversifying our workforce over the last seven years and we are starting to see the impact of that, with 40% of our trainee roles now filled by females. We also have some great role models here that new women coming into the industry can really look up to, and that’s why we know there is even more we can do.”

For more information about International Women in Engineering Day and the reasons to celebrate it, click here: https://www.inwed.org.uk/

Or if you are a woman looking for a role in the engineering or manufacturing industries, click here for our careers pages: People (polartechnology.co.uk)

Polar Technology developing innovative solutions for hydrogen storage

Tue, 11 Jun 2024 09:00:01 GMT

Polar Technology addressing challenges of hydrogen storage within aerospace industry.

Hydrogen storage is of growing significance within the aviation industry, with many viewing it as a potential solution in the challenge to reduce carbon impact. Currently, aviation emissions are responsible for 3.5% of climate warming caused by humans, indicating an urgent need to develop more sustainable alternatives.

The appeal of Hydrogen is that, when generated from renewable sources, it would emit zero carbon dioxide emissions, whilst still maintaining current flight routes. This interest is evident in Airbus’s commitment to developing the world’s first fully hydrogen-powered aircraft by 2035. Hydrogen does however pose several challenges in terms of fuel storage, as it delivers less energy by volume than kerosene fuel, meaning huge quantities would be required to power an aircraft.

Polar Technology Management Group has a wealth of experience in the design, development and manufacture of technologies to support the “hydrogen economy”. Leveraging expertise in lightweight, composite high-pressure cylinders and hydraulic accumulators, and in the area of cryogenic liquified gas storage down to liquid helium temperatures, Polar Technology have developed solutions for gaseous and liquid H2 storage.

These solutions have been focused on three main areas: extremely light weight cylinders offering industry-leading gravimetric efficiency, the novel ‘Hydrogen in a box Solution’ where volumetric efficiency and space constraints of high-pressure cylinders are important, as well as technologies for the cryogenic storage of liquified H2.

The “Hydrogen in a Box” Solution

The ‘Hydrogen in a Box’ design offers greater volumetric efficiency than other hydrogen storage solutions, allowing for a more distributed storage solution, making it perfect for the demands of aerospace.

There is a great deal of flexibility around the geometry of these parts, opening up new opportunities to efficiently store hydrogen in places where cylinders would not be appropriate, such as in the wings of an aircraft or under the floor and possibly even as part of the structure itself.

The technology is compatible with a variety of different liner materials, from metallic to composite components. It has also been extensively pressure tested, with existing prototypes being evaluated for both 350Bar and 700Bar applications, with options for liquid H2 storage under evaluation.

Polar Technology’s solution minimises the amount of empty or lost space within the vessel, as well as enabling the capacity to easily increase volume when required. Furthermore, “Hydrogen in a Box” has the capacity to integrate valves and control systems within the design, removing the need for extra manifolds at system level, whilst it doesn’t require the use of a chassis to hold separate vessels together, unlike many similar products on the market.

Kieran Burley, the Lead Engineer on the project, said “This is a very exciting time to be working on hydrogen storage solutions; there are so many opportunities for innovation, optimization and integration. Combining novel design solutions with innovative manufacturing processes means we can package hydrogen storage efficiently in a series of co-dependent chambers to form a storage bank, rather than fitting a number of standard independent cylinders into the space.”

How Polar Technology Can Help

Alongside ultra-light weight cylinders, “Hydrogen in a Box” is a fitting flagship product for Polar Technology, as it showcases many of the organisation’s engineering and manufacturing capabilities, featuring parts created by utilising metallic fabrication techniques, as well as their expertise in both moulded and wound composites.

Daniel Chilcott, Group Business Development Director, said “Enabling technologies for a sustainable and heathier future is rooted in our vision and ethos as an organisation. Looking at the huge opportunity that exists for technological advance in Hydrogen, together with the impact on carbon reduction potential. I am certain Polar Technology’s solutions such as ‘Hydrogen in a Box’ can provide our customers significant overall system improvements.”

With an experienced and highly qualified engineering team, Polar Technology have supplied their products and services on many of the major aerospace programmes delivered in the last 10 years, operating through their brands, Lentus Composites and SST Technology. As the industry continues to explore ways of reducing carbon impact, Polar Technology are in a strong position to offer high-performance solutions.

If you are interested in how our hydrogen storage solutions could benefit your business, please get in touch here.

It's Men's Health Week

Mon, 10 Jun 2024 07:32:24 GMT

Hear from our colleagues on how they've utilised the support services that are available.

This week is Men’s Health Week, and we are celebrating it by highlighting all the support we have available for our employees, as well as bringing in external experts to further champion everything to do with men’s health and wellbeing.

The purpose of Men’s Health Week is to act as a reminder of the importance of proactively addressing and managing health issues and to encourage men to take charge of their own wellbeing.

This links perfectly with our own internal policies, which centre around the “Five Ways” approach. This suggests that building the following five actions into our day-to-day lives can make a big, positive difference:

1. Connect- Make and sustain connections with the people around you, including family, friends and colleagues.

2. Be active- Discover a physical activity that you enjoy and that suits your level of mobility and fitness.

3. Take notice- Be aware of the world around you and what you are feeling and savour the moment as much as you can.

4. Keep learning- Trying something new or taking on new responsibilities can make you feel more confident, as well as being fun.

5. Give- Relating yourself, and your happiness, to that of the wider community can be incredibly rewarding and helps to create further connections.

However, sometimes these simple fixes aren’t enough to cope with the pressures on our mind and body, and that’s where our internal support systems and range of benefits are so important. We spoke to our colleagues about how they’ve used the different types of support available to build healthier and happier lives:

Health Cash Plan:

The Health Cash Plan, provided in partnership with BHSF, allows Polar Technology employees to claim cash reimbursements for routine and emergency healthcare. It is available through a number of different packages, for both individuals and families, at different price brackets. The types of healthcare eligible for the reimbursements include dental costs, optical costs, therapy treatments, maternity/paternity and hospital inpatient costs.

Our Production Manager for Moulded Composites, has taken out a ‘Gold Family Package’, meaning his wife and children can also benefit from the scheme. He said “It’s almost paid for itself now, given how many things that we’ve been able to claim for. I went though some bad back problems last year and I’ve been having regular appointments with the chiropractor to help manage and prevent the issues, and I’m able to claim 75% of the costs back each time.”

“The app is so easy to use; you can track all your used and available benefits and the claims you’ve made so far, and then you can easily find the option you’re looking for when you process a new claim. All you need to do is add an electronic receipt or photo and that’s it, the money goes straight into your bank about three or four days later. It’s a no-brainer!”

Mental Health First Aiders/My Possible Self App

A key component of general health is mental wellbeing, and this is an issue that men in particular often suffer in silence with. We have trained Mental Health First Aiders on-site who are available to speak to colleagues when needed, and an app called ‘My Possible Self’ which offers interactive tools and activities to help manage your own mental wellbeing.

One colleague, who wished to remain anonymous, opened up about his experiences of the services available: “I think that I’d been really struggling with anxiety and depression for about three months before I reached out to Frankie, one of our Mental Health First Aiders. Following the discussions I had with Frankie and the management team, I was allowed to take some time away from work and then work out a schedule for easing me back in at my own pace.”

“I never felt any pressure from anyone to rush back before I was ready, and my team were so supportive. Frankie has been incredible; she checked in with me when I was away from the business and having someone to talk to that you trust is so important.”Over a year later, the difference has been significant, with the colleague now working his normal hours and above. He did recognise that this was an issue that may never fully go away and still uses the app occasionally to keep on top of how he’s feeling.

He was keen to encourage others to take advantage of the support that is available: “I honestly don’t know where I’d be if I didn’t have the support. It’s also nothing to be embarrassed about and I hope that sharing my experience will help others come forward. If it helps one person, it will have been worth it.”

Employee Assistance Programme

After speaking to our Mental Health First Aiders, they can refer colleagues to our Employee Assistance Programme, a professional counselling service that can offer help with major life issues including stress, debt and bereavement, as well as other information and guidance.

This service is available free of charge for the first six sessions, and is strictly confidential. It only takes a brief description of the issues to be matched with a qualified counsellor, who can then offer support for as many sessions as is required.

One of our Machine Shop Controllers began using the counselling service about two months ago to help manage a difficult situation he was having in his home life: “I was struggling to deal with my partner’s son, who has severe ADHD, in the most constructive way and it was causing tension in our home. I had an initial consultation with the service, who referred me to the right person, and I’ve since had five sessions, with two more booked in the diary.”

“They have helped me to manage my own reactions and reconsider my behaviour, so that I can deal with the situations in a calmer way. I’ve also been able to better understand the behaviour of my partner’s son, through advice from my counsellor and reading online articles about ADHD. It’s definitely led to a better state of mind for me, and a better atmosphere at home.”

He recommended the service to anybody who might be struggling with an issue in their personal lives or at work: “It was so easy to set up and start speaking with someone. Since starting the sessions, I’ve noticed a massive difference.”

Polar Technology becomes members of the FAC

Tue, 21 May 2024 07:58:25 GMT

Polar Technology joins Farnborough Aerospace Consortium (FAC)

We are delighted to announce that we have become members of the Farnborough Aerospace Consortium (FAC), the longest-established aerospace and defence body within the UK, who currently boast over 250 members.

The benefits of an FAC membership include facilitating local and international trading, technology transfer and development and sharing of best practice, ultimately allowing members to boost their market share.

This opportunity is reflective of Polar Technology’s aims to build on our existing relationships within the aerospace and defence sector, as well as exploring new ones.

For more information about the FAC and its membership, click here: FAC Home

Polar Technology and Supacat UK Partner up for the Jackal Program

Tue, 16 Apr 2024 07:56:08 GMT

Safety is pinnacle

Polar Technology Management Group Ltd (Polar Technology) are pleased to announce the recent partnership with Supacat UK to deliver a key part of the enhanced safety roll over protection (ROPs) assembly for the High Mobility Transporter (HMT) vehicle, termed the Jackal by the British Army.

With expertise in the engineering of precision fabricated assemblies, tube manipulation, high integrity coded welding, managing supply chains and delivering to tight regulatory standards, Polar Technology are the perfect match for this program.

Polar Technology are providing safety solutions to the roll over protection system on the Jackal vehicle and enhancing the value chain of the program and working closely with Supacat’s assembly partner Babcock.

Tom Lloyd, Head of Commercial said, “Polar Technology have been engaged with Supacat for nearly 10 years. We are delighted to be contracted on the new build Jackal 3 program and our relationship has grown and improved significantly. We look forward to working with Supacat to support them in bringing new platforms, upgrading in-service vehicles and technologies to the market for many years to come.”

Lizzie Jones, Supacat Operations Director said, “Supacat has been working with Polar Technology on the enhanced ROPS Parts to ensure the certified parts we designed are made to our specification, and our tooling allows for a repeatable manufacturing process. We look forward to working with Polar Technology on future projects.”

Polar Technology’s team of engineers and highly skilled fabricators produce critical safety components for a range of industries for vehicles working in the harshest environments and working with Supacat is the pinnacle of safety.

The Polar Team gets up close and personal to the Supacat Jackal vehicle

Wed, 10 Apr 2024 09:10:20 GMT

Getting an insight into the Jackal

Last Thursday saw the Polar Team enjoy their latest team “Boar and Beef” lunch with a difference. This time the team were presented with a Jackal vehicle alongside their team lunch. The Jackal gave the team the opportunity to experience “first hand” where the parts they design and manufacture end up.

“It was great to see where the parts we produce go…the Jackal is a great vehicle, now I understand a lot more where they end up and what a difference we make…it’s like being part of a bigger team, thank you” says a Polar production member.

Polar would like to thank Supacat for their kind support in bringing the Jackal up to Eynsham.

Polar presents £3,000 to Maggie's Oxford

Fri, 01 Mar 2024 14:56:42 GMT

Polar raises money to support the local charity Maggie's Oxford

On the 29th February, Polar Technology presented Maggie's Oxford with a cheque of £3,000 which was raised by the team in a series of events carried out in 2023.

Maggie's is a hospice for all cancer care, Maggie's centre is a space for being together or for a moment alone, for getting going again or for meeting people who just get it.

The charity was nominated in 2022 by the team at Polar Technology to be their annual charity to support.

Tracy Dewhirst, Group Marketing Manager said, "it has been a pleasure to work with Maggie's and support them as much as we can. The social committee and I enjoyed thinking up fundraising events to support Maggie's; from bake sales, lottery draws, raffles to racing events. It was great fun and all for a good cause too!"

Pip Dingle, Centre Fundraising Manager Oxford also added, "Wow, what an incredible total! This is great news and will help so many people, thank you so much - to you and all at Polar. Thank you again for everything you have done for Maggie's."

Excitement for a New Machine to add to the Polar Technology In-house Machining Capabilities

Tue, 23 Jan 2024 15:07:26 GMT

New Year, New Machine...

Polar Technology are pleased to announce the first large commissioning of the year is underway.

So far with the hard work from the onsite maintenance team and sub contractors, we have the utilities in, and the floor bolts installed.

Thomas Rogers, Polar's Machine Shop Manager said, "Today we've just taken delivery of the machine bed and the spindle. Over the next couple of weeks, the team at Kingsburys will continue to build and deliver and we look forward to sharing more updates on this".

The acquisition of this Zimmermann FZ33c further strengthens both Polar's capacity and capabilities within composite machining, and along with the purchase last year of Concept Tooling, bolsters the overall goal as a business to offer a complete and robust in house engineering solution service.

For further information on our machining capabilities and how we can help you, please contact us and we will be happy to discuss your requirments.

Team Polar runs the local Eynsham 10k

Sun, 26 Nov 2023 19:16:43 GMT

Well done to Team Polar who ran the local Eynsham 10k in freezing conditions

The Polar Group have been headline sponsors for the local Eynsham 10k since 2015.

On 26th November, Team Polar experienced a very cold and frosty morning race, along with over 500 other athletes.

Mike Dewhirst, Co-Founder said "It was a pleasure to sponsor such a lovely event. So many supporters along the way and the marshals did a grand job!"

Seeing is believing...

Tue, 08 Aug 2023 09:16:32 GMT

Supporting urban air mobility and electrifying air travel

Last Thursday, The Polar Team were invited down to Bristol to witness one of the early flight tests for Aircraft 1.

Alex Edge, Strategic Business Manager at Polar commented, "It was great to see this - a fantastic joint accomplishment of a mature, well equipped supply chain that had brought this vision of electric flight to fruition".

To view the aircraft video, please click on the link below.

https://www.linkedin.com/feed/update/urn:li:activity:7094597942811979777

We like to do things differently!

Thu, 22 Jun 2023 13:44:57 GMT

Polar Team having pies in the sun!

The Polar Team were treated with a British themed 'Pie, mash and gravy' team lunch today as a thank you for all their continuous hard work.

"It has now become a bit of a treat and we are always looking forward to what the next themed lunch will be! Its a nice reward and it gives us a chance to have lunch with our colleagues in the sun!" said a colleague.

When you think of lunch in the sun, pie and mash may not always be your first thought but for those who knows us at Polar - we like to do things differently!

Polar and Moog Controls collaborate on Hydrogen Storage Solutions

Mon, 19 Jun 2023 10:03:02 GMT

A joint project on Hydrogen Storage Solutions

Polar Technology Management Group Ltd has developed a novel concept in hydrogen storage and is working with Moog Controls to develop an integrated hydrogen storage and management solution termed “Hydrogen in a Box”. The system benefits are based around optimal packaging efficiency, gravimetric efficiency and the ability to integrate valves and control systems into one optimised solution.

A six-month long technology evaluation process has been completed and test hardware will now be manufactured. The design has been evaluated as Type 3 and Type 4 version for both 350Bar and 700Bar applications.

Kieran Burley, Lead Engineer at Polar Technology said “This is a very exciting time to be working on hydrogen storage solutions, there are so many opportunities for innovation, optimization and integration. Combining novel design solutions along with innovative manufacturing processes we can package hydrogen storage efficiently in a series of co-dependent chambers forming a storage bank, rather than fitting a number of standard independent cylinders into the space.”

Mark Lawton, Moog’s General Manager of the Aircraft Control Components division stated, “It has been great for Moog to collaborate with Polar in providing novel methods to efficiently store and release hydrogen in mission critical environments. This project is an integral part of Moog’s commitment to develop future green technology for commercial air travel.”

The joint project will establish an appropriate specification and set of system level requirements for hydrogen storage and delivery systems for aircraft and other Industrial applications.

Polar Technology Management Group acquires the assets of Concept Tooling Ltd

Sun, 26 Mar 2023 15:47:26 GMT

We are delighted to welcome on board the team from Bicester!

On 14 March 2023, Polar Technology acquired the assets of Concept Tooling Ltd, this will support existing customers from both businesses further accelerating growth and diversifying the organisation.

Scott Roberts, Co-Founder at Polar Technology said, “The acquisition of the assets of Concept Tooling significantly strengthens Polar Technology’s composite machining capability and capacity. We are delighted to welcome on board the team at Bicester who bring complementary skills to our operation and we look forward to accelerating our plans for future growth”.

Martin Dorney, Director at Concept Tooling added, ”This is great news for the team here at Concept Tooling as we can draw upon the skills and experience from the team at Polar by working together to meet both our customer’s requirements whilst maintaining the high level of service in place”.

Polar Technology will continue all operations from the same location in Bicester, retain key staff and offer the customers the same high level of service and support.

Polar announces £2000 donation to Helen & Douglas House

Tue, 14 Mar 2023 08:26:55 GMT

The Polar Technology Management Group announces a £2,000 donation to local charity Helen & Douglas House

(Above: Polar Technology Group Chairman Mike Dewhirst and Helen & Douglas House Senior Philanthropy & Partnerships Manager Liza Clothier)

Mike Dewhirst, Chairman from Polar Technology Group said, “It has been a great pleasure to work with a local charity that our team chose to support. With the restrictions of the pandemic it proved a little difficult to organise fundraising events at the start but our internal social committee team became very creative with new fundraising ideas so it never stopped us adding to the charity pot!”.

“It was wonderful news and thank you so much for the £2,000 donation. Working with Polar on some events was so much fun. Hopefully our paths will cross again!” said Nardia Bissmire at Helen & Douglas House.

Health and Safety iOSH Leading Safely

Wed, 01 Mar 2023 14:22:19 GMT

Polar Group fully trained in iOSH Health & Safety Leading Safely

All staff have undertaken COSHH training. Nearly 30 managers have been trained to IOSH leading safely. The Polar Board also undertook a full iOSH leading safely course further demonstrating Polar’s true commitment to Health and Safety.

Farnborough Air Show here we come!

Thu, 23 Jun 2022 14:10:57 GMT

Getting ready for the first exhibition this year!

The Sales and Marketing within the Polar Group are currently getting ready for the forthcoming event - The Farnborough Air Show on the 18-22nd July.

With less than a month away, both Lentus Composites and SST Technology are excited to be back at an exhibition showcasing our products and networking face-to-face with industry colleagues.

"It has been a while since the pandemic and the team here are looking forward to exhibiting our latest products and talking to visitors at the show. Please come and meet the team and I on stand 3820, Hall 3 . They will be happy to see you!" , said Daniel Chilcott, Group Business Development Director.

For more details on Farnborough Air Show, please visit www.farnboroughairshow.com

On Your Feet Polar!

Thu, 28 Apr 2022 14:30:32 GMT

Polar Group on our feet!

The Polar Group team took part in today's national awareness day along with over two million desk-based workers across Britain by taking a lunch walk of over 2 miles in Oxfordshire. #sitless #movemore

On Your Feet Britain is a fun way to reboot and energize your workplace habits.

"With such busy lives we live, it is nice to get out, when the sun is shining with your work colleagues for a walk to help increase concentration and to refresh our minds", said Dan Brooks, Head of Production & Planning.

#OnYourFeetBritain #OYF2022

Doing our bit!

Fri, 04 Mar 2022 10:32:22 GMT

The Polar Technology Group supports Ukraine.

With the current situation in Ukraine, it comes with little surprise that the Polar Technology Group are stepping up to help.

One of our manufacturing managers Marcin Sysa comes from a village in Poland, 20 minutes from the Ukraine border. Poland has seen 350,000 Ukrainian refugees enter their country. Many have arrived with absolutely nothing which has put a huge strain on Poland to provide the very basic of resources and they are in desperate need of support. Marcin is working with a group here in the UK who are sending supplies to Poland and has asked for any donations.

"We are overwhelmed with the amount of supplies donated by my colleagues here at the Polar Technology Group. It shows the true support of everyone is times of need. Thank you everyone." said Marcin.

The lorry departs the UK later today.

Latest feature in Manufacturing Today

Wed, 29 Sep 2021 14:20:42 GMT

In the latest Manufacturing Today, Polar Technology Group features an article on the latest news and vision of the Group.

To read about this, click here and head to P86 of the magazine (or P88-89 of the PDF).

If you have any questions please do not hesitate to contact us direct.

Celebrating Long Service Awards

Thu, 19 Aug 2021 14:18:38 GMT

On Wednesday 18th August saw a group of colleagues being treated to a well deserved lunch with senior members of the Polar Management Team.

The celebratory lunch was for the Long Service Awards at Lentus Composites and SST Technology – celebrating five and 10 years of service within the Polar Technology Group.

“It was great to see how many of the team have remained loyal throughout the years. Feels like one big family!”, said Mike Dewhirst, Co-chairman.

The five year service awards were presented with a £400 voucher and the ten year service awards were presented with our personalised special TAG Heuer watch.

Flexible office space available!

Mon, 10 May 2021 14:11:15 GMT

Flexible office space available at Signal Court, Eynsham in Oxfordshire, as a whole (9,785 sq ft) or in individual suites from 150 sq ft upwards. For more details click here .

Contact our agents Adrian Chan for more information.

BGF invests £10 million in specialist engineering company

Thu, 15 Apr 2021 14:05:01 GMT

BGF – the UK’s most active growth capital investor – has announced a £10 million investment in Polar Technology Management Group, an Oxfordshire-based business which manufactures high-performance carbon and metal components for the automotive, medical and aerospace/defence sectors.

BGF’s investment will be used to support Polar Technology Management Group’s planned move into a state-of-the-art 100,000 sq. ft. facility at Horizon Technology Park in Eynsham, Oxfordshire, doubling the size of its production capacity and creating over 110 new jobs in the next two years. The new facility is expected to be fully up and running during 2021.

Polar Technology Management Group was established in 2012 by Scott Roberts and Mike Dewhirst. Currently employing over 200 people, the business designs, develops and manufactures products and technology based around advanced composite materials, emerging metal processes and metallic fabrications.

With a focus on high-tech R&D, Polar Technology Management Group’s key clients include a range of technology specialist companies in the medical and aerospace industries.

The company is highly embedded in the automotive sector, working with F1 manufacturers, whilst also producing parts for high performance ‘Hypercars’.

Scott Roberts, Co-founder of Polar Technology Management Group, said: “We are delighted to welcome BGF into a partnership that has secured an injection of £10m of fresh funding into Polar Technology Management Group. This will enable us to grow faster, support our customers better and provide job security to our existing team of highly skilled, dedicated, employees. The deal will also create hundreds of new jobs in the West Oxfordshire area over the next three years with investment planned in clean, sustainable, technologies supporting our expanding manufacturing base.”

Greg Norman, investor at BGF, led the deal alongside Liam Pursall, Jack Teasdale and BGF’s head of manufacturing Mark Bryant.

Greg said: “We have known the team at Polar Technology Management Group for some time and seen them deliver year-on-year. We are excited to partner with them to support the long-term growth of the business. The company has an impressive management team in Scott, Mike and Dale, and some very exciting technologies both already delivered and in development. We look forward to the growth of this exciting company as it looks to the future.”

Polar’s Four Technology Streams

Tue, 30 Mar 2021 13:59:28 GMT

Polar Technology is leading the way to an environmentally sustainable future through it’s four Technology Streams of Electrification, Power Transmission, Light Weight Structures and Fluid/Heat Transfer.

These optimised, lightweight and efficient technologies are delivered through the Polar Group Companies of SST Technology and Lentus Composites to a global portfolio of customers and partners.

For more information on how we can help you with your requirements, please email info@lentuscomposites.co.uk or info@sstubetechnology.com .

Helping our employees

Thu, 28 Jan 2021 14:55:26 GMT

The Polar Technology Group are proud to roll out their new Computer Scheme in support of employees’ children who are currently home-schooling.

During the recent lockdown, schools are closed and children are yet again schooling from home. With lessons going online, some households may struggle to get hold of PCs or laptops.

The Polar Technology Group (SST Technology and Lentus Composites), recognise this and decided to introduce the new Computer Scheme. This scheme is where staff can purchase a laptop for a child’s home-schooling at a discounted rate with costs being spread over 12 months.

An employee said, “This scheme has helped me out tremendously and it is nice to see my employer supporting me during this pandemic”.

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Polar Technology partners with Trive Capital

Polar Technology are delighted to announce that they have secured additional growth capital from a new partner, Trive Capital, through a majority equity investment.

Supporting the Next Generation of Lightweight, High-Performance UAV Structures

The UAV market is one of the fastest growing markets across the past decade and looks set to continue to its remarkable trajectory. Some projections indicate that it could contribute £45 billion to the UK economy alone by 2030.

The Importance of UK-Based SME’s in the Defence Industry

The UK Defence industry is undergoing its most transformative period since the end of the Cold War. The Government has announced the largest sustained increase in Defence spending in a generation, with the figure rising to 2.6% of GDP by the end of 2027. ﻿

Polar Technology In The Community

Polar Technology are proud to be an active part of our local community in Eynsham, Oxfordshire.

Five Benefits of Filament Winding

Polar Technology are market leaders in the process of filament winding, creating specialist, lightweight composite components which are ideally suited to the demands of high-performance industries.

Five Benefits of Advanced Precision Fabrication

Advanced, precision fabrication is one of the key areas of expertise we possess at Polar Technology, with our skilled fabrication department having generations of experience in producing durable, enabling metallic assemblies

Polar Technology win Trailblazers Award

We are delighted to announce we have been selected as a 2025 Wired Trailblazer by WIRED Magazine and HSBC UK.

Ultima Forma and Polar Technology’s leading edge protection layer enhancing durability for aerospace and defence applications

Last year, Ultima Forma and Polar Technology announced the launch of the LEEF (Leading Edge Electro Forms) project, collaborating to improve the ability of a composite structure to withstand erosion, impact and corrosion in extreme operating conditions.

The project has gone from strength and strength and is now attracting interest from leading Aerospace and Defence organisations, who are exploring potential applications for the technology.

Polar Technology selected by ISTEC to manufacture the sub-frame for the USAF Grey Wolf helicopter weapon integration mounts

Polar Technology have been selected by ISTEC, one of the UK’s leading designers and manufacturers of specialist weapons integration mounts, to manufacture the sub-frame required to connect the ISTEC designed weapons mount to the United States Air Force (USAF) Grey Wolf Helicopter. ﻿

From Concept to Solution: A Guide to How We Support our Customers

At Polar Technology, we take a project from concept to solution, partnering with our customers to identify the right technology and manufacturing method for the end application, before managing every stage of the process all the way through to volume production. ﻿

Polar Technology Operating at Pinnacle of Automotive Excellence

With the recent showcasing of the latest innovations in the automotive industry at the Goodwood Festival of Speed, it seems a fitting time to highlight the role our composite and metallic components play in the sector’s continual pursuit of high-performance.

25 Years of Engineering and Manufacturing Excellence

The heritage of Polar Technology has recently reached the twenty-five-year mark. From its origins in 2000, the company has evolved from a small, specialist fabrication business into a global supplier for market-leading customers across a diverse range of high-performance industries.

Polar Technology awarded Breakthrough Culture Award

Polar Technology are delighted to announce that we have been selected for the Breakthrough Culture Award: Growth Edition in 2025. The award is a 12-month certification designed to recognise the next wave of UK companies who are passionate about creating a thriving workplace.

Our Solutions for a Sustainable Future

As part of our vision to create enabling technologies for a sustainable and healthier future, Polar Technology have focused on the development of products for alternative, clean energy sources supporting the transport sector’s move to electrification.

Polar Technology Powering Formula E for 2025

With the 2024-25 Formula E season well underway and the Miami E-prix having taken place this weekend, it’s a great time to look at the innovative and sustainable technology that is powering the world’s leading competition for electrically powered single-seater racing cars.

BAE Systems honors Polar Technology with a ‘Partner 2 Win’ Gold Tier Award

Polar Technology today announced it received a Gold Tier Award from BAE Systems’ Partner 2 Win program.

Our Solutions for the Defence Industry

The defence industry is one of our key end-markets at Polar Technology, and one currently undergoing significant growth.

﻿ Utilising our expertise in both composite components and advanced precision fabrications, we are able to offer enabling, durable and lightweight solutions that are ideally suited for critical, demanding applications.

Polar Technology developing its future leaders with Leadership Academy programme

Polar Technology has established a specialist, in-house Leadership Academy to provide all current and future managers with the necessary skills for effective leadership.

National Apprenticeship Week: Cain and Luke's Stories

This week is National Apprenticeship Week; the UK’s annual commemoration of apprenticeships and skills, and the value that they bring both the apprentices and their employers.

A guide to our innovative hydroforming process

Within the extensive capabilities for metallic processes and fabrications at Polar Technology is a novel, specialist hydroforming process.

A guide to our cutting-edge machining facilities

We utilise our extensive and capable machine shop to support and enhance our manufacturing processes.

Polar Technology implementing brand-new filament winding machine to enhance high-volume manufacturing

We have recently installed a brand-new filament winding machine as part of a designated, world-class manufacturing cell

How we make pressure vessels

We are specialists in the design, development and manufacture of composite pressure vessels for the storage and transport of fluids and gases at high pressures.

A guide to our specialist, high-performance moulded department

Our skilled team can support with a variety of complex, high-volume projects.

A Day in the Life of a Development Engineer

Ben, one of our Development Engineers, takes us through his typical day at Polar Technology.

How we make fabricated structures

A step-by-step guide to the process we follow in creating bespoke, advanced fabricated structures.

Polar Technology developing composite retention sleeves to support the electrification of the transport sector

We have developed high-speed optimised Carbon Fibre Reinforced Polymer (CFRP) sleeves for use in electric rotor applications

How we build and integrate additive manufacturing products

A comprehensive guide to the steps involved in the process of producing high-quality additive products for use in demanding, high-performance applications.

Polar Technology’s machining solutions supporting production of 3D printed products

Through utilising solutions from MSP, our machining capabilities have gone from strength to strength.

Our Solutions for the Aerospace Industry

In honour of National Aviation Day, we're celebrating the innovation at the core of our aerospace offering.

Polar Technology supporting The Hummingbird Centre as charity of choice for 2024

We will be raising money for the cancer support and therapy centre in Bicester.

Health and Safety Committee Relaunched

Polar Technology have recently relaunched their Health and Safety Committee. ﻿

Polar Technology celebrate Cycle to Work Day

To mark the occasion, we were offering an incentive for the person who cycled the furthest distance, and a bacon sandwich and hot drink for everyone who had a go!

Polar Technology and Ultima Forma collaborating on erosion protection solution for aerospace applications.

Ultima Forma and Polar Technology are collaborating to expand the adoption of carbon fibre composite (CFRP) materials for aerospace applications.

Polar Technology supporting the development of Striker® II fighter-pilot helmet

Polar Technology awarded multi-year contract to support BAE Systems in the development of the Striker ® II fighter-pilot helmet for the UK Royal Air Force.

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How we build transmission shafts

A guide to producing lightweight, energy-efficient transmission components

Polar Technology and Intelligent Energy combine tech to deliver endurance system for UAVs

Innovative new system significantly increases UAV range

How moulded composite products are made

A comprehensive guide to developing high-performance composite products.

The UK Defence industry is undergoing its most transformative period since the end of the Cold War. The Government has announced the largest sustained increase in Defence spending in a generation, with the figure rising to 2.6% of GDP by the end of 2027.

Polar Technology have been selected by ISTEC, one of the UK’s leading designers and manufacturers of specialist weapons integration mounts, to manufacture the sub-frame required to connect the ISTEC designed weapons mount to the United States Air Force (USAF) Grey Wolf Helicopter.

At Polar Technology, we take a project from concept to solution, partnering with our customers to identify the right technology and manufacturing method for the end application, before managing every stage of the process all the way through to volume production.

Utilising our expertise in both composite components and advanced precision fabrications, we are able to offer enabling, durable and lightweight solutions that are ideally suited for critical, demanding applications.

Polar Technology have recently relaunched their Health and Safety Committee.

Polar Technology awarded multi-year contract to support BAE Systems in the development of the Striker ^® II fighter-pilot helmet for the UK Royal Air Force.