Rolls-Royce Converts Tornado Parts to 3D Printing Powders

Rolls-Royce has successfully showcased Tornado 2 Tempest, an innovative recycling initiative that converts decommissioned Royal Air Force (RAF) Tornado components into metal powders for 3D printing. These powders have been used to produce parts for the Orpheus small engine concept, a key element of the Future Combat Air System (FCAS) program. This initiative demonstrates the potential of recycling surplus defense materials into advanced components for next-generation aircraft.

The Tornado 2 Tempest project, spearheaded by Defence Equipment and Support’s (DE&S) Defence Recycling & Disposals Team (DRDT) in collaboration with the Ministry of Defence (MOD) FCAS team, Rolls-Royce, and Additive Manufacturing Solutions Limited (AMS), aims to establish a circular economy framework for defense applications. The project was supported by funding from UK Strategic Command’s Defence Support Organisation under its Circular Economics for Defence Concept Note.

The project identified high-value strategic metals such as titanium, aluminum, and steel within surplus MOD assets. These materials were refined into feedstock powders for additive manufacturing. Titanium components, including jet engine compressor blades, were atomized and repurposed into 3D-printed nose cones and compressor blades. Rolls-Royce installed a 3D-printed nose cone on an Orpheus test engine, confirming its safety and performance under real-world conditions.

“This project exemplifies the sustainability principles at the heart of the FCAS Sustainability Strategy and MOD Defence Support Strategy. At Rolls-Royce, we are committed to advancing circular economy practices and digital innovations to build a lower-carbon and digitally driven business. Tornado 2 Tempest is a testament to what can be achieved through collaboration between the MOD, industry, and SMEs,” said Andrew Eady, vice president of FCAS sustainability, Rolls-Royce.

The initiative also introduced a Digital Product Passport to track material provenance and lifecycle data, enhancing material management while reducing the risks of counterfeit materials entering the supply chain.

“By recycling high-value metals, this approach not only cuts costs and mitigates supply challenges but also enables the production of components that are lighter, stronger, and more durable than traditionally forged alternatives,” said Thomas Powell, senior commercial manager for strategic and submarine recycling, DRDT.

More than 80 professionals, including graduate apprentices and experts from DRDT and Rolls-Royce, collaborated to integrate traditional expertise with cutting-edge manufacturing technologies.

The success of Tornado 2 Tempest was recognized with a commendation from the MOD’s Chief of Defence Logistics and Support (CDLS). “At AMS, our mission is ‘Innovative Solutions for a Sustainable Future.’ This project has proven our ability to deliver real-world solutions that strengthen supply chains and demonstrate the power of circular economy principles in defense applications,” said Robert Higham, director, AMS.