Innovative Resource Recovery: A Circular Leap in Aeronautics
Innovation: The Tornado 2 Tempest project represents a monumental stride towards establishing a sustainable and circular aeronautics industry. It showcases the immense potential of recycling and additive manufacturing in reducing environmental impact and enhancing production efficiency. This project not only benefits the defense sector but also sets a benchmark for other industries striving to adopt sustainable practices. Link to defensemirrow.com video
The Tornado 2 Tempest project, a collaborative endeavor between Rolls-Royce and the Royal Air Force (RAF), marks a significant milestone in the application of circular economy principles within the aeronautics industry. This initiative ingeniously repurposes decommissioned Tornado aircraft components, transforming them into metal powder for 3D printing spare parts used in aircraft engines. This innovative approach not only drastically reduces waste and mitigates environmental impact but also paves the way for sustainable manufacturing practices within the aerospace sector.
At the heart of this project lies the objective to validate the feasibility and myriad benefits of recycling aircraft components through advanced processes like atomization and 3D printing. The focus material is titanium, a lightweight yet robust metal, abundantly found in Tornado aircraft components. The process involves disassembling and cleaning these components, followed by their conversion into metal powder through atomization. This powder is then utilized in 3D printing to create new parts, which undergo rigorous testing to ensure their safety and suitability. These parts are primarily intended for the Orpheus engine, a key component of the Future Combat Air System (FCAS) program, with potential applications extending to the Tempest program.
The implications of this project are far-reaching, touching upon sustainability, efficiency, innovation, and economy. It significantly curtails waste, lessens the demand for virgin material extraction, and diminishes environmental impact. The project also enables on-demand component production, reduces waste, and optimizes the use of valuable materials. Furthermore, it fosters the adoption of 3D printing and advanced technologies, alongside the development of novel materials and production processes. Economically, it leads to reduced production costs and delivery times, while also creating new business opportunities in recycling and additive manufacturing. Ensuring safety and traceability, the project incorporates a Digital Product Passport to track material provenance and assure component quality.
This project is a collaborative effort involving Rolls-Royce, the Royal Air Force (RAF), Defence Equipment and Support’s (DE&S) Defence Recycling & Disposals Team (DRDT), and Additive Manufacturing Solutions Limited (AMS). It is supported by funding from the UK Strategic Command’s Defence Support Organisation, under the Circular Economics for Defence Concept Note program.
Andrew Eady, Rolls-Royce VP FCAS Sustainability, emphasizes the project’s pivotal role in Rolls-Royce’s sustainability strategy and its commitment to circular economy practices. Thomas Powell, DRDT’s Strategic & Submarine Recycling Senior Commercial Manager, highlights the project’s economic and environmental advantages, particularly its capacity to produce lighter, stronger components.
