UK pioneers 3D printing of aircraft parts using recycled titanium

Above: First flight of an aircraft fitted with a bracket made from 98% recycled titanium.
Copyright QinetiQ Ltd

The flight – believed to be a world first – was conducted by QinetiQ’s Flight Test Organisation and took place at MoD Boscombe Down in Wiltshire. 

The component flown was a hinge, forming part of an Air Data Boom, attached to a QinetiQ-owned A109S helicopter which is being developed for ETPS, the world-renowned flight test training school. QinetiQ designed and integrated the hinge while it was manufactured by AMS Ltd. using titanium recovered from a decommissioned aircraft. 

AMS Ltd.’s proprietary process recycles scrap metal and creates powder which meets the quality requirements needed for the printing of a new product, achieving 97% efficiency and minimising material loss – particularly valuable for high-cost, hard-to-source metals like titanium. The process also uses 93.5% less CO2e, offering a step change in environmental impact, in comparison to traditional supply chains.

Titanium is commonly used in defence platforms, due to its high strength-to-weight ratio and its resistance to corrosion. Global demand for the material has increased due to urbanisation and infrastructure growth, with China and Russia as the largest suppliers of aerospace grade titanium globally. 

The approach adopted by AMS Ltd. and QinetiQ could reduce UK dependency on imported titanium, with AMS Ltd. estimating that the UK could become self-sufficient, if all the titanium held in scrap aircraft was extracted for recycling.

Simon Galt, Managing Director Air, 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, AMS Director & CEO, commented: "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."