Recycling fighter jet parts: 3D printing as a sustainable solution for aviation

An innovative recycling project in the UK shows how decommissioned fighter jets can be used to manufacture new components for modern military jets. Parts from old Tornado jets are processed into metal powder and transformed into new components for the future Tempest fighter aircraft using additive manufacturing. This process could help to reduce dependence on global supply chains for strategic metals and at the same time improve the aviation industry’s environmental footprint.

The recycling of titanium components from Tornado engines was a key aspect of the project. In particular, titanium compressor blades and nose cones were successfully atomized and reused for 3D printing. The finished components were then integrated into a Rolls-Royce Opheus test engine and underwent extensive safety and suitability testing.

“The Tornado 2 Tempest project highlights the creativity, ingenuity and innovation defence employs in our approach to national security. By working with key industry partners, we can deliver savings, reduce reliance on global supply chains and ensure our Armed Forces have the very best kit to keep our country safe. Not only does this initiative have a positive impact on the environment and national security, it supports the domestic defence industry acting as an engine for growth, which is at the heart of Plan for Change”, said Maria Eagle, Minister for Defence Procurement and Industry.

The project was carried out in collaboration between the British Ministry of Defense, Rolls-Royce and Additive Manufacturing Solutions Limited (AMS). In addition to the technological benefits, economic impetus was also generated, including the creation of new jobs in the field of additive manufacturing. A digital product passport system was also implemented to track the origin and life cycle of materials. This could help to increase transparency in the supply chain and prevent the use of counterfeit materials in the future.

“The Tornado 2 Tempest project exemplifies the forward-thinking sustainability principles embedded in the FCAS Sustainability Strategy and MoD Defence Support Strategy. This project is bold, exciting and innovative, and a demonstration of exemplary collaboration between the MoD, industry and SME, furthering the drive for circular economy practices and innovative digital enablers in Defence“, said Andrew Eady, Rolls-Royce.

“At AMS our tagline is ‘Innovative Solutions for a Sustainable Future’ and we were confident our innovations and ideas would have a great bearing on the future of a resilient supply. 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”, said Robert Higham, AMS Director.

The successful implementation of this project demonstrates the potential of additive manufacturing in military aviation. In the long term, such processes could not only help to conserve resources, but also improve the availability of critical materials for the defense industry.