Leonardo and Uplift360 partnership turns waste into flight

Image courtesy Uplift360

Using its proprietary low-temperature chemical recycling process, ChemR, Uplift360 extracted high-quality, reusable carbon fibre from a rotor blade taken from a EH101, the forerunner of the AW101. Once destined for incineration or landfill, the reclaimed fibres were repurposed into a structural component — proving the performance and potential of chemically recycled aerospace-grade composites.

The project began under an R&D contract with Leonardo in May 2025 and focused on testing ChemR’s ability to process complex composite waste. Uplift360 exceeded the brief by not only recovering the material but also validating its use in manufacturing, showing how end-of-life components can re-enter the value chain.

This collaboration directly supports the UK’s Strategic Defence Review focus on strengthening supply chain resilience. Carbon fibre is critical to aerospace and military systems, yet the UK lacks sufficient recovery infrastructure. ChemR helps close that gap, turning waste into a secure, domestic resource.

Sam Staincliffe, Co-founder and CEO of Uplift360, said: “At Uplift360, we believe advanced materials should never go to waste. This project with Leonardo shows how ChemR can turn what was once unrecyclable into mission-ready material – supporting a more resilient and sovereign Defence supply chain.”

Clive Higgins, UK Chair and CEO of Leonardo, said: “Material recirculation is a key component of our Leonardo Sustainability Plan, helping us to reduce our waste and reuse materials where possible, ultimately building resilience in our supply chains. Collaborating with innovators such as Uplift360, we can demonstrate how sustainability not only creates positive environmental and social impacts but delivers business and economic benefits.”