Direct Plating Process Could Reduce Rotor Blade Cost and Weight | Aviation International News

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Direct Plating Could Reduce Rotor Blade Cost and Weight

Alpha Metalcraft Group is in talks with eVTOL aircraft developers

Alpha Metalcraft Group — Alpha Metalcraft Group is devising new manufacturing processes to save cost and weight for tasks such as making guards for rotor blades.

By Charles Alcock • Managing Editor

February 17, 2026

Alpha Metalcraft Group (AMG) believes it can reduce the cost and complexity of specialist manufacturing tasks such as applying the leading-edge guards that prolong the service life of carbon-fiber rotary blades. The company is working with OEMs, including developers of eVTOL aircraft, to introduce an electroplating process in which nickel is directly deposited on composite surfaces rather than making the guards separately and then fitting them to the blades.

The current process involves expensive stainless steel mandrel forms for shaping the nickel abrasion guards. This approach is also time-consuming, with five separate steps plus two or more transportation stages to get the finished items installed on the blades.

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