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Source: Industry Handout
The United Kingdom’s Ministry of Defence (MOD) has initiated an innovative approach to developing its next-generation Tempest fighter aircraft by recycling components from decommissioned Tornado jets. This strategy aims to reduce reliance on foreign-sourced materials and enhance sustainability in military manufacturing.
DMLS (Direct Metal Laser Sintering)
The process involves extracting high-quality metals, such as titanium, from retired Tornado aircraft. These materials are then ground into a fine powder, known as “feedstock,” suitable for additive manufacturing or 3D printing. This feedstock is utilized to produce new components for the Tempest program.
Decommissioned Tornado Fighter Jet
Project TAMPA has been established to advance the adoption of additive manufacturing (AM) and enhance material availability across the defense sector. In November, defense manufacturer Babcock successfully completed the first phase of work for the initiative. The Babcock team has been collaborating across multiple domains to develop innovative solutions for complex components. This includes critical parts for the L118 Light Gun, the 4.5-inch naval gun used on Type 23 frigates, and the torpedo launch systems for both the Astute- and Dreadnought-class submarines.
In collaboration with Rolls-Royce, the MOD successfully tested this approach by recycling Tornado engine compressor blades into 3D-printed nose cones and compressor blades for the Orpheus engine, a small engine concept within the Future Combat Air System (FCAS) program. The 3D-printed components passed all suitability and safety checks, demonstrating the viability of this recycling method for future aircraft development.
Tempest 6th-Generation Fighter from BAE Systems
This initiative not only offers potential cost savings but also strengthens supply chain resilience by reducing dependence on global sources for critical and high-value metals. Additionally, components produced through this recycling process are reported to be lighter, stronger, and more durable than those manufactured using traditional forging techniques.
Image of the UK’s concept model for the next generation jet fighter “Tempest”
The Tempest program is a collaborative effort involving the UK, Italy, and Japan, aiming to revolutionize sustainable aircraft manufacturing. The project plans to conduct the first test flight in 2026, with the goal of entering service by 2035.
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