QinetiQ, working with Additive Manufacturing Solutions Limited (AMS Ltd.), has conducted what it says is the first flight of a helicopter containing a 3D printed structural component made from recycled titanium. The test flight took place at MOD Boscombe Down in Wiltshire using QinetiQ’s Flight Test Organisation.
The component was a hinge that forms part of an Air Data Boom on a QinetiQ-owned A109S helicopter being developed for ETPS flight test training school. QinetiQ handled the design and integration of the hinge, while AMS Ltd. manufactured it using titanium recovered from a decommissioned aircraft.
AMS Ltd.’s recycling process converts scrap metal into powder that meets quality requirements for 3D printing new products. The company reports the process achieves 97% efficiency with minimal material loss and uses 93.5% less CO2e compared to traditional supply chains.
The partnership aims to reduce UK dependency on imported titanium, with China and Russia currently serving as the largest global suppliers of aerospace-grade titanium. AMS Ltd. estimates the UK could become self-sufficient in titanium if all material from scrap aircraft was extracted for recycling.
“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,” said Simon Galt, Managing Director Air at QinetiQ.
Rob Higham, AMS Director & CEO, commented: “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.”
Source: qinetiq.com
