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RAF recycles old fighter jet parts into 3D-printed components for next-gen aircraft, boosting sustainability.
In a groundbreaking development, the UK’s Royal Air Force (RAF) is transforming obsolete fighter jets into valuable raw materials for the next generation of aircraft through advanced 3D printing techniques. This innovation, spearheaded by Robert Higham of Additive Manufacturing Solutions, allows for the recycling of key aerospace materials, such as Ti64—a titanium alloy, into new aircraft components. This method not only reduces environmental impact but also addresses material sourcing challenges, particularly from countries facing sanctions.
This starts by recycling old turbine blades from retired RAF aircraft, such as the Panavia Tornado. These have served between 1980 and 2019. The process melts them and atomises into spherical particles using a high-pressure jet of argon gas to form a fine powder. The powder then goes into the 3D printers, with which the new components are to be created. These are used in the next-generation RAF systems, including even a nose cone for a proof-of-concept Orpheus jet engine designed by Rolls Royce.
This innovative approach is more efficient than traditional manufacturing, which can be costly and environmentally taxing. With the use of recycled parts, the RAF makes new, high-quality components with minimal waste while reducing reliance on foreign material suppliers. The precision in printing complex components further increases the sustainability and cost-effectiveness of the process.
The tremendous potential of 3D printing in the aerospace sector is highlighted through this technique, which effectively welds powder into layers as thin as human hair. Such an advanced method will be brought into play within the Future Combat Air System with the proposed sixth-generation Tempest fighter jet and thus will continue to place the UK at the leading edge of military aviation technology.
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