UK-based defense and security QinetiQ has completed what it says is the world’s first flight of an aircraft carrying a structural component 3D printed from recycled titanium.
The flight was conducted by QinetiQ’s Flight Test Organisation at MoD Boscombe Down, UK in partnership with metal additive manufacturing company Additive Manufacturing Solutions (AMS). The test involved a QinetiQ-owned Agusta A109S helicopter.
The 3D printed component was a hinge forming part of an Air Data Boom fitted to the helicopter. QinetiQ designed and integrated the hinge, while AMS manufactured it using laser powder bed fusion (LPBF) from titanium powder recovered from a decommissioned aircraft. The material was 98% recycled.
AMS’s proprietary recycling process converts scrap titanium into powder meeting the quality standards required for additive manufacturing of structural components, achieving 97% material efficiency and minimizing waste. Compared with conventional supply chains, the process also generates 93.5% fewer CO₂e emissions.
Titanium is widely used in aerospace due to its high strength-to-weight ratio and corrosion resistance. Global demand has grown in recent years, driven by urbanization and infrastructure development, with China and Russia currently the largest international suppliers of aerospace-grade titanium.
AMS estimates the UK could become self-sufficient in aerospace-grade titanium if material from decommissioned aircraft were systematically extracted and recycled, potentially reducing dependency on overseas supply chains.
The flight builds on an Innovate UK-funded project led by AMS in 2023 that examined the feasibility of using recycled metallic materials in additive manufacturing to support a high-value circular economy for the aerospace supply chain. That same year, AMS began working with the UK’s Ministry of Defence Defence Equipment & Support to explore the technical feasibility of recovering critical materials from surplus defense assets.
Simon Galt, managing director, air at QinetiQ said, “Our testing and engineering expertise is helping to prove the technology which will reduce the UK’s dependency on other nations for aerospace grade titanium. Not only are we helping to strengthen UK supply chains, we are also leading the rest of the world in the very latest 3D printing technology.”
Rob Higham, director and CEO, AMS, said, “AMS has tirelessly built momentum and expertise within the additive powder market, with a sharp focus on providing recycled feedstocks. This milestone reflects the dedication of our team and QinetiQ’s commitment to a more resilient and sustainable future.”
