15th Sep 2025
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.”
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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
