Old Fighter Jets Can Be Melted Down and 3D Printed into New Ones

From Scrap to Sky: Transforming Retired Jets into Next-Gen Aircraft

In a breakthrough that blends sustainability with cutting-edge technology, experts are now turning decommissioned fighter jets into high-performance components for future aircraft. This innovative process not only reduces waste but also addresses critical supply issues—such as avoiding reliance on materials from sanctioned regions like Russia.

A New Lease on Life for Old Jets

Imagine fighter jets that first soared in the 1970s being reborn as parts for modern warplanes. The UK’s Royal Air Force (RAF) is poised to benefit from this pioneering approach. Instead of discarding obsolete or damaged jets, these aircraft are now melted down and converted into a fine powder. This powder serves as the raw material for 3D printing new, high-quality components, heralding a new era of sustainable aerospace manufacturing.

The Science Behind the Transformation

At the heart of this innovation is a novel recycling technique developed by Robert Higham at Additive Manufacturing Solutions. The method focuses on reclaiming crucial materials like Ti64—a titanium alloy containing 6% aluminium and 4% vanadium. The UK Ministry of Defence has vast reserves of Ti64 locked away in retired aircraft and surplus parts. By reprocessing these materials, the RAF can significantly cut costs while reducing environmental impact.

Higham explains that the process begins by melting down old parts and then spraying the molten metal into a high-pressure jet of argon gas. This rapid cooling causes the metal to form spherical, raindrop-like droplets—a key step since jagged particles can clog 3D printers. “It’s very similar to the way rain becomes hailstones,” he notes, highlighting the natural elegance of the technique.

Precision 3D Printing for Aerospace Excellence

Once transformed into a uniform powder, the material is fed into advanced 3D printers. These printers build new components by meticulously welding layers together—each layer measuring roughly half the thickness of a human hair. The result is a finely crafted part that meets the rigorous standards of modern aerospace engineering.

In an impressive first demonstration of this technology, the recycled powder was used to 3D print a nose cone for an Orpheus jet engine. Rolls Royce is currently developing this engine for the Future Combat Air System (FCAS), a next-generation project that also includes the BAE Systems Tempest—a proposed sixth-generation fighter jet for the RAF.

A Sustainable Future for Aerospace

As Higham reflects on the potential of this breakthrough, he emphasizes the cost and environmental benefits: “The world is more expensive and complex than it used to be. Our approach allows us to make products as cost-effectively as possible.” By recycling old fighter jets into new, precision-engineered components, the aerospace industry is taking a significant step towards a more sustainable future.

For more on innovations that merge technology and sustainability, stay tuned to The Horizons Times.