QinetiQ has claimed a first for global aviation: flying an aircraft with 3D-printed parts created from recycled titanium.
The British firm recovered metallic components from a decommissioned aircraft and used them to produce a hinge that attached an air data boom to an A109 helicopter.
The work was done in collaboration with Lancashire-based Additive Manufacturing Solutions Limited (AMS Ltd.), which converted the scrap metal into aerospace-grade titanium powder for use in the 3D-printing process.
Its proprietary method reportedly has a 97-percent efficiency rate, reduces waste, and could give military forces an edge when working with expensive materials like titanium.
Beyond efficiency, the process also slashes carbon emissions by over 94 percent compared with conventional supply chains, improving the environmental footprint of aircraft production.
“AMS has tirelessly built momentum and expertise within the additive powder market, with a sharp focus on providing recycled feedstocks,” AMS Director and Chief Executive Officer Rob Higham said.
“This milestone reflects the dedication of our team and QinetiQ’s commitment to a more resilient and sustainable future.”
Toward a Self-Reliant Metal Supply
Titanium is critical for defense platforms due to its structural integrity and resistance to corrosion, with China and Russia said to be dominating aerospace-grade supply.
QinetiQ and AMS said the UK could reduce reliance on imports by creating a domestic supply chain using the process of recycling metal from decommissioned aircraft.
“Our testing and engineering expertise is helping to prove the technology which will reduce the UK’s dependency on other nations for aerospace-grade titanium,” QinetiQ Managing Director Simon Galt stated.
“Not only are we helping to strengthen UK supply chains, we are also leading the rest of the world in the very latest 3D printing technology.”
