Polar Manufacturing FZ-LLC
Polar Manufacturing FZ-LLC offers the following sub-contract services:
We design composite parts using advanced 3D CAD tools, ensuring each product is lightweight, strong, and ready for manufacture. Our focus is on function, style, and performance—whether for aerospace, sport, or industrial use. Every design reflects a balance of technical precision, modern aesthetics, and practical, real-world application.
We use CAD and CAM software to develop precision tooling and production-ready composite parts. Our engineering process includes 3D modelling, mould design, ply book generation, and machining files—ensuring each part fits, functions, and performs. Everything is developed with manufacturing in mind, reducing rework and streamlining the production process.
We use high-resolution 3D scanning to capture precise surface data for inspection, reverse engineering, and quality control. Whether validating parts against CAD, recreating legacy components, or tracking production accuracy, our scanning process ensures speed, reliability, and traceability. Ideal for composite surfaces, complex geometries, and critical dimensional verification.
We offer high-precision CNC machining for composite tooling, trim fixtures, and components. Using CAD/CAM software, we machine foam, epoxy board, aluminium, and composite parts to tight tolerances—ensuring accuracy, repeatability, and fast turnaround.
We use 3D printing for rapid prototyping, design validation, and producing custom jigs and fixtures. It enables fast iteration, supports complex geometries, and reduces lead times. Integrated into our workflow, this capability enhances accuracy, speeds up development, and provides practical, cost-effective solutions across tooling, testing, and low-volume production.
We manufacture production-ready tooling through various methods, including CNC-machined epoxy master’s with composite moulds or direct aluminium female mould tools. Each tool is tailored to customer requirements, with a strong focus on precision, dimensional accuracy, thermal stability, and repeatability—ensuring reliable performance across autoclave, oven, and press-cure composite processes.
We manufacture composite components using a range of processes, including prepreg layup and curing, wet layup, press moulding, LRTM, and resin infusion. Each method is selected based on material, geometry, and volume—ensuring the final part meets the customer’s exact specifications, performance targets, and production requirements.
We offer professional spray painting and coating for composite parts, including primers, high-build finishes, and clear coats. Surface preparation, masking, and application are carefully controlled to ensure adhesion, durability, and a high-quality finish. Our process supports cosmetic, protective, and functional coatings across a range of composite components.
We apply flock coatings to composite components for a soft, textured finish ideal for grip, noise reduction, or aesthetic detailing. The process involves adhesive application followed by electrostatic fibre deposition, ensuring even coverage and strong adhesion. Commonly used for interiors, padding, and functional surface enhancement.
We carry out bonded and mechanical assembly of composite components, including B-surface fixings, inserts, fasteners, ancillary parts, and brackets. Using jigs, templates, and controlled processes, we deliver full assemblies, ready for installation, ensuring a complete solution that meets both cosmetic and functional requirements.
With over 30 years of experience, we deliver high-quality, cost-effective wiring harnesses for motorsport, automotive, aerospace, and defence. From concept to production, including complex assemblies, we follow APQP processes and provide full documentation such as PPAP, PSW, and ISIR where required.
We help clients set up and scale efficiently advising on equipment procurement, factory layouts, floorplans, recruitment, material selection, and supply chain. We also identify suitable production processes such as prepreg, infusion, LRTM, or press moulding. Our expertise saves time, reduces cost, and avoids common mistakes—accelerating your path to production.
Clear, honest communication—no delays, no confusion. Customers are empowered to make informed decisions.
We hold ourselves to the highest standards—precision, consistency, and pride in everything we deliver.
We solve challenges through innovative thinking and a collaborative mindset—giving you better outcomes, faster.