Armour Edge Expands Manufacturing and Blade Database

Allen and Joel are joined by Will Howell from Armour Edge in Edinburgh, Scotland. They discuss how Armour Edge's semi-rigid polymer shields protect against leading edge erosion in harsh environments, the simplified installation process designed for rope access technicians, and the company's expansion into North American manufacturing ahead of the 2026 blade season. Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard's StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTube, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary's "Engineering with Rosie" YouTube channel here. Have a question we can answer on the show? Email us! Allen Hall: Will welcome back to the program.  Will Howell: Thanks so much for having me guys. Nice to see you.  Allen Hall: So Edinborough is the home of Armor Edge.  Will Howell: Yes, indeed.  Allen Hall: Yeah. And we went to visit your facility a couple of days ago. Really impressive. There's a lot going on there. Will Howell: Absolutely. Absolutely. Yeah. So the, we've been in the facility for, um, a couple of years now, and it's really just all part of our expansion as we continue to. To, uh, grow as a business?  Allen Hall: Uh, well the thing that struck me first was efficiency. If you're gonna be in wind, do you need to be efficient?  Will Howell: Yeah,  Allen Hall: exactly. You have  Will Howell: to  be,  Will Howell: look, we know that we are a, a relatively small team, but we're, we are, we are very reactive and we are gonna be always responding to the, the requests. The, the market drive for us internationally now is where we are really focusing. And even though we've got our small base from there, we're exporting internationally around the world. And so. Yeah, I'm, I'm, I'm glad you guys came by and kind of saw what we're up to.  Joel Saxum: If we could ask one thing, this is what we would ask. Turn up the heat. Turn down the wind. Turn off the rain.  Will Howell: Yeah, I'm [00:01:00] sorry about that. Yeah. Yeah, it's, uh, there's not much we can do about that at the moment.  Joel Saxum: Well, I'll tell you what, if, if you're talking leading Edge protection products, leading edge protection shield. Born from an area that's rainy, that has heavy rain erosion, that understands,  Will Howell: we know, we know rain. We know rain. Yes. Look, we've been out in the North Sea now for over, over, over five years. These things are just being abused by Mother Nature out there and, you know, but we've, we are, we're getting really good results consistently. Um, the products lasting really well against that, against that weather. And I think what's interesting for us as well is it's, it's not just the Scottish rain and the ice and the snow. We're, we're getting good results out in the. The planes in the Midwest as well now. Yeah. And yeah, so yeah, very uh, universal products, we hope,  Joel Saxum: I mean, so this is one of the things we always talk about. When you talk wind turbine blades and you listen to the manufacturers, a lot of them sit in Denmark where the problem is mist in the air, it is rain, it is droplet size. It's all the conversation you hear. But where we [00:02:00] see wind is dust, bugs, those kind of things. Like, it's, it's different stuff, right? So like I'm, I live in Texas. One of the things that's beautiful about my home in Austin is when I look to the west in the, at, in the evening, it's bright red skies all the time. Well, that means there's dust in the air.  Will Howell: Yeah.  Joel Saxum: Right. And that's, and when I look west, what am I looking at? 23,000 turbines out in West Texas. Right. So everything out there is getting beat up where we look at, um, inspections of turbines and we see turbines that are 1, 2, 3 years old that look like they've been in operation for 15 years. Will Howell: Yeah. Yeah.  Joel Saxum: There's nothing left of them.  Will Howell: I know. And. You know, people use analogies like, oh, it looks like it's been sand sandblasted. But it it has, it has, it is sandblasted, you know, we've, we've now conducted testing where we have literally taken kind of aerospace level testing and blasted sand at these shields, and they're super resilient. But it has to be that universal products of resisting the water droplet that the mist, that side [00:03:00] of the, of the erosion problem, but also the particulate matter in the air. And there've been some of the. Places that we've installed. There was actually one site where they had a local, um, open cast mining nearby, and there was like marble particulate matter in the air. And these machines were getting trash in a couple couple of seasons. And again, we've been on there now for, I think now is our third year in that particular site. And again, really good results.  Joel Saxum: Well, I think, um, I mean, we did take some B roll when we were at your facility. And again, thanks for welcoming Sam. We love doing those. It's, uh, but you showed us your installation methodology, and maybe we'll show some of that with our producer Claire on mm-hmm. On this video. Uh, but the, the way you guys design your installation methodology to be simple and robust, easy for the technicians to make sure they can't get it wrong in the field because they got enough other things to worry about. Will Howell: Uh, you know, I think, I think that's been a big part of our, of our kind of design ethos since the, since the early days in the, in the r and d phase, it wasn't only finding a robust material for the LEP Shields, a robust. [00:04:00]Adhesive to bond them on, but it's the, it's the kind of higher level. How do you actually get that onto a blade in the field by a rope or standing in a platform up in the, up in the winds And so, yeah, understanding what the technicians are having to go through in order to install this stuff. And that then feeds into your quality. 'cause you can have the best lab results in the world from your perfect installation sitting in a factory somewhere. But actually it's the guys on ropes that are doing the, doing the hard work out there.  Joel Saxum: We see that all the time with our, like with our lightning protection products like. People, can you give us this lab test? Like we can, we'll stack you up with lab tests. Mm-hmm. But what we really wanna show you is the test from the field.  Will Howell: Yeah, yeah, yeah.  Joel Saxum: The test that where it's been sitting, soaking, getting hit by lightning. Mm-hmm. All of these things for years and years and years. Yeah. That's the results we wanna show you. 'cause those are real.  Will Howell: Absolutely. Yeah, yeah, yeah. Makes  Allen Hall: the demo you gave us to install the shields and it's basically a series of shields that go along the leading edge of the blade, sort of two parts of that one. Obviously you're trying to recover the lost power, the a EP, that's, that tends to be the big thing, [00:05:00] except in some locations, like Joel's pointed out, it's not that the leading edge is just kind of lightly beat up. It's really beat up.  Will Howell: Yeah. Yeah.  Allen Hall: And you're trying to prevent that from happening or to just to provide some protection, uh, if you're just sort of category three, and I, I wanna walk through that for a minute because the demo you did was really interesting and I. It, it made sense once you watch the process happen. Mm-hmm. It's really clear, but you're able to take sort of cat three damage on the leading edge and not have to go back and do a lot of repair to it, which is where the vast majority of the funds are used to sort of get the blade to a point you can apply leading product. Oh yeah. Yeah. With Armor Edge, you don't really need to do that. Will Howell: Yeah. And I think that that that really comes into the. Into the value proposition of the, of the whole, of the whole process. If the labor costs and the downtime of the machines, there's so much value in that. And so if you can reduce the repair time or just remove it completely, because you can install [00:06:00] directly on top of existing erosion, you've really saved some significant cost out of the, out of the job. And that's really only just by function of the design of the shields. We are a, a semi rigid polymer material, so we don't conform to the existing erosion that's on the surface. So. Yes. If you, if you have a cap four or five and you have some structural glass repair that needs to happen to maintain the integrity of the blades, you still need to complete that repair. You don't need to go any further. So if you've only got a one, two, or three, you're talking the fillers, the putties on, on the surface. You don't need to, to replace those. Just apply our high build adhesive, get the shield on top, and you're finished.  Allen Hall: And so you start at the tip with a, a tip. Shield and then you work your way, kind of Lego wise up up the leading edge of the blade. Yeah,  Will Howell: yeah, yeah.  Allen Hall: It's really straightforward and, and the, the system you're using, the adhesives you're using, and the techniques are really adapted for the technician. What I watched you do, I'm like, oh, wow, this is really [00:07:00] slick because there's been a lot of thought going into this. You have done this. Hundreds of times yourself before you've shipped it out to  Will Howell: the world. Yeah, exactly. And, and that was, that was a big part of the, part of the r and d process is to, again, as I said, it's, it's not just affecting these applications in a lab environment. It's saying, how does this feel up on a rope? How does it feel strapped into your work, into your work position? ...