Individual parts from retired fighter jets have been ground down and 3D printed into new components suitable for the UK’s next generation of military aircraft – a first of its kind initiative for the Royal Air Force.

The innovative recycling project has seen parts from old Tornado aircraft turned into powered metal and used to 3D print new components suitable for Tempest jets. This is a great example of UK-developed technology of the future, and demonstrates UK defence industry as an engine for growth and a key part of the Government’s Plan for Change.

The development could save taxpayer money, reduce the UK’s reliance on global supply chains of critical and high value metals and produce components that are lighter, stronger, and longer lasting than those made through traditional forging techniques.

Many of the Ministry of Defence’s surplus assets contain strategic metals, including high quality steel, aluminium, and titanium, and the Tornado 2 Tempest project team have been identifying whether some of these components could be atomised into powders – known as “feedstock” – for additive manufacturing to make new parts.

Tornado parts containing titanium, including jet engine compressor blades from a low-pressure air compressor, were selected. They were cleaned, successfully atomised and recycled into a 3D printed nose cone and compressor blades by Additive Manufacturing Solutions Limited (AMS) for Orpheus – Rolls-Royce’s small engine concept that is part of the MOD’s Future Combat Air System (FCAS) programme delivering Tempest.

The nose cone was fitted onto an Orpheus test engine and passed suitability and safety checks – demonstrating the technique has potential use in the sixth-generation jet.

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