Rolls-Royce, one of the world’s leading engine supplier in business aviation, has achieved a significant breakthrough in aerospace recycling through its ‘Tornado 2 Tempest’ programme by successfully transforming Royal Air Force (RAF) Tornado components into 3D Printed Orpheus Engine parts. Rolls-Royce achieved this by converting the Tornado components into metal powder that was used to 3D print the new jet engine parts.
The project, which demonstrates the practical application of circular manufacturing in defence aviation, has successfully produced new components for the company’s Orpheus small engine concept, which is part of Europe’s Future Combat Air System (FCAS) project. This advancement marks a crucial step towards sustainable manufacturing in the aerospace sector.
Recycling RAF Tornado parts to 3D Printed Orpheus Engine
The recycling initiative focuses on repurposing Ministry of Defence’s (MOD) surplus assets, particularly those containing strategic metals such as high-quality steel, aluminium, and titanium. In a notable achievement, the team successfully recycled titanium from jet engine compressor blades, converting them into powder form for 3D printing new components.
The recycled materials were used to create a nose cone and compressor blades, which were subsequently tested on an Orpheus test engine. The tests yielded positive results, confirming the safety and suitability of these recycled components for future applications in the aerospace industry.
Thomas Powell, DRDT’s Strategic & Submarine Recycling Senior Commercial Manager, explained the broader benefits: “This solution can reduce the costs and burden of sourcing critical and high-value metals while producing components that are lighter, strong and longer lasting than those made through traditional forging techniques.”
Collaborative Effort Drives Success
The initiative represents a joint effort between several organisations, including Defence Equipment and Support’s (DE&S) Defence Recycling & Disposals Team, the MOD FCAS team, Rolls-Royce, and Additive Manufacturing Solutions Limited (AMS). More than 80 professionals, including DRDT’s commercial graduates and Rolls-Royce graduate apprentices, contributed to the project.
“The Tornado 2 Tempest project exemplifies the forward-thinking sustainability principles embedded in the FCAS Sustainability Strategy and MOD Defence Support Strategy.”
– Andrew Eady, Rolls-Royce VP FCAS Sustainability
Eady added, “At Rolls-Royce, we continue to be leaders in circular economy practices and innovative digital enablers to support our steps to be 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 SME can deliver sustainable and technologically advanced solutions.”
The project, funded by UK Strategic Command’s Defence Support Organisation, also incorporated a Digital Product Passport system to track material allocation and prevent counterfeit materials. This innovation has earned the team a Chief of Defence Logistics and Support Commendation for their contributions to frontline support.
Squadron Leader Rob, FCAS’ Sustainability Requirements Manager, highlighted the strategic benefits: “Through the expected lifecycle of the UK’s FCAS, we expect access to critical materials to be challenged, as global supply chains become increasingly disrupted and competitive.”
Robert Higham, AMS Director, expressed pride in the project’s achievements: “This project turned our proposed solutions into a reality, and we have been humbled and grateful to the MOD and Rolls-Royce for allowing us to showcase our capability to deliver game-changing circular economy processes and parts in Defence.”
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