Additive Manufacturing Solutions Ltd (AMS) is working with the UK Ministry of Defense (MOD) and Rolls-Royce to recycle components from decommissioned Tornado fighter jets for use in the new Tempest jets. The aim of the project is to reuse high-quality metals from the decommissioned aircraft and produce new components through additive manufacturing.
The recycling process begins with the dismantling of the Tornado aircraft in order to extract recyclable materials such as titanium. These metals are then processed into powder, which serves as the starting material for 3D printing. AMS has successfully used this method to produce a 3D-printed nose cone and fan blades for Rolls-Royce’s Orpheus engine. The Orpheus engine is a central component of the Future Combat Air System (FCAS), which is to produce the Tempest fighter aircraft. The manufactured components were installed in a test engine and subjected to extensive safety and suitability tests. These tests confirmed the suitability of the recycling process for military aviation applications.
Rob Higham stated: “This project turned our proposed solutions into a reality, and we have been very humbled and grateful to the MOD and Rolls Royce, for allowing us to showcase our capability to deliver game-changing circular economy processes and parts in Defence.”
The company was awarded the Chief of Defence Logistics and Support (CDLS) Commendation for its commitment, which recognizes the team’s achievements in improving logistics support. This project underlines the importance of additive manufacturing for military aviation and could be increasingly used in the future.
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