Rolls-Royce is to launch an innovative defence recycling programme with the Tornado 2 Tempest project , an initiative that converts obsolete components of the Royal Air Force ( RAF ) Tornado into metal powder to manufacture new parts using 3D printing.
The Tornado 2 Tempest project: From waste to innovation
The Orpheus engine , part of the UK’s Future Combat Air System ( FCAS ) programme, has been the first to benefit from this technology, demonstrating its viability for the next generation of fighter aircraft, including the Tempest platform .
The project is led by Defence Equipment and Support ( DE&S ) and the UK Ministry of Defence (MOD) , identifying that many disused assets contain strategic metals such as titanium, aluminium and high-grade steel.
Through an atomization process , components such as compressor blades have been transformed into raw material, allowing the 3D printing of new parts, including a front cone and compressor blades .
Once the recycled parts were manufactured, Rolls-Royce carried out tests on an Orpheus engine , validating its performance and safety. Furthermore, the results confirm that this methodology is effective, and can be applied to other propulsion systems in defence .
At Rolls-Royce, we continue to be a leader in circular economy practices and innovative digital enablers to support our steps towards a lower carbon and digitally enabled business. Tornado 2 Tempest is a bold, exciting and innovative project and a demonstration of how excellent collaboration between the MOD, industry and SMEs can deliver sustainable and technologically advanced solutions.
Andrew Eady, Vice President, Sustainability, FCAS, Rolls-Royce.
A Digital Product Passport , a technology that documents the life cycle of materials, has also been implemented, ensuring transparency and authenticity in the reuse of resources. Furthermore, more than 80 specialists, including engineers from the company, MOD experts and developers from Additive Manufacturing Solutions Limited ( AMS ), have worked on the initiative, combining experience and technology to revolutionise defence manufacturing.
At AMS, our motto is ‘Innovative solutions for a sustainable future’ and we were confident that our innovations and ideas would have a major influence on the future of resilient supply. This project turned the solutions we proposed into reality and we are honoured and grateful to the Ministry of Defence and Rolls-Royce for allowing us to showcase our ability to deliver game-changing circular economy processes and parts in Defence.
Robert Higham, director of AMS.
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Source and photos: Rolls-Royce
