British defense leader QinetiQ has reached a significant milestone in sustainable defense manufacturing, successfully conducting the first flight of a 3D-printed structural component made from recycled titanium. The test took place at MOD Boscombe Down in Wiltshire, featuring a 3D-printed hinge installed on a QinetiQ-owned A109S helicopter. This aircraft is being developed for the prestigious Empire Test Pilots’ School (ETPS).
The hinge acts as a crucial attachment point for an Air Data Boom, which is essential for measuring airspeed and angle of attack. Maintaining the hinge’s structural integrity is vital during flight testing, as any failure could lead to serious issues, disrupting vital instrumentation data needed for pilot training. Designed by QinetiQ and manufactured by Additive Manufacturing Solutions Limited (AMS Ltd.), this component was crafted from titanium that was salvaged from decommissioned aircraft. This flight signifies a pivotal advancement in validating that critical flight hardware can be effectively repurposed from scrap via additive manufacturing.
AMS Ltd. employs a proprietary atomization process that converts recycled scrap metal into powder. This method achieves an impressive material efficiency of 97%, minimizing waste. While the specific powder bed fusion process used for the hinge was not disclosed, AMS possesses capabilities in both laser and electron beam powder bed fusion. Their manufacturing technique reportedly emits 93.5% less CO2e compared to conventional supply chains.
Recycling titanium is particularly advantageous due to the metal’s properties—it is lightweight, robust, and highly resistant to corrosion, making it ideal for defense applications. Despite its vast availability, sourcing titanium remains costly and complex, driving the appeal of recycling. The demand for titanium spans multiple sectors, including aerospace and infrastructure, with major suppliers currently located in China and Russia. Hence, by promoting titanium recycling, the UK could lessen its reliance on foreign imports. AMS estimates that if the UK collected all titanium from scrap aircraft, self-sufficiency could be achieved.
Simon Galt, Managing Director of Air at QinetiQ, emphasized that their engineering efforts illustrate how this technology could reduce the UK’s need for imported aerospace-grade titanium. Rob Higham, Director & CEO of AMS, highlighted their commitment to providing recycled feedstocks, marking this flight’s success as a testament to their efforts toward a sustainable future.
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