Rolls-Royce is repurposing parts from retired Panavia Tornado fighter-bombers to produce components for the new Tempest fighter jets. This initiative, known as the Tornado 2 Tempest project, involves breaking down strategic metals like titanium, steel, and aluminum from old aircraft and transforming them into feedstock for additive manufacturing.
The Royal Air Force stated on February 5 that these metals could be atomized into powders for 3D printing new parts. Rolls-Royce confirmed that titanium from Tornado engine parts is being used to create 3D printed nose cones and compressor blades through a contract with Additive Manufacturing Solutions, Limited.
BAE Systems is also employing 3D printing technology in its Tempest project. A report from July 26, 2024, highlighted BAE’s use of additive manufacturing to produce structural parts and molds more efficiently. The process includes Hot Isostatic Pressing (HIP), which compacts powdered titanium under heat and pressure to minimize waste and reduce lead times.
Additive manufacturing offers significant advantages over traditional methods by reducing weight, cost, and production time while providing sustainable solutions. Kevin Myers of Collins Aerospace emphasized these benefits in a statement from June 10, 2022.
The British Ministry of Defence’s Defence Recycling & Disposals Team sees this approach as cost-effective and environmentally beneficial. It results in lighter and stronger components than those made through conventional forging techniques.
Rolls-Royce’s Orpheus engine development exemplifies the potential of additive manufacturing in aviation. Initially designed to move from concept to testbed within 18 months instead of three years, Orpheus aims to deliver an efficient turbofan jet engine with low fuel consumption.
The Tornado to Tempest project aligns with the UK’s goals for a reliable supply chain and environmental sustainability through a circular economy model. Additionally, a digital product passport is being developed using QR codes linked to online databases to prevent counterfeit products in defense supply chains.
