QinetiQ has completed what may be the world’s first flight of an aircraft containing a 3D printed structural component produced from recycled titanium.
The flight was carried out by QinetiQ’s Flight Test Organisation at MOD Boscombe Down in Wiltshire, in partnership with Additive Manufacturing Solutions Limited (AMS Ltd.).
The component flown was a hinge forming part of an Air Data Boom fitted to a QinetiQ-owned A109S helicopter, which is being developed for use by the Empire Test Pilots’ School (ETPS). QinetiQ designed and integrated the hinge, while AMS Ltd. manufactured it using titanium recovered from a decommissioned aircraft. According to the companies, AMS Ltd.’s recycling process converts scrap titanium into additive manufacturing powder which meets the quality standards required for aerospace printing. The process is said to achieve 97% efficiency, minimising material loss, and to reduce carbon emissions by 93.5% compared to traditional supply chains.
Titanium is widely used in defence aviation due to its strength-to-weight ratio and resistance to corrosion, but global demand has increased, with China and Russia among the largest suppliers of aerospace grade titanium. QinetiQ said the approach could help reduce the UK’s dependency on imported titanium. AMS Ltd. has estimated that the UK could potentially become self-sufficient in titanium supply if scrap aircraft material were systematically recovered and recycled.
Simon Galt, Managing Director Air at QinetiQ, said: “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. 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.”
Rob Higham, Director and CEO of AMS Ltd., added: “AMS has tirelessly built momentum and expertise within the additive powder market, with a sharp focus on providing recycled feedstocks. This milestone reflects the dedication of our team and QinetiQ’s commitment to a more resilient and sustainable future.”
