Rolls-Royce recycles Tornado parts for 3D-printed components

The Tornado 2 Tempest project has successfully converted surplus military components into powdered metal for additive manufacturing in the UK’s Future Combat Air System.

Rolls-Royce has contributed to the Tornado 2 Tempest initiative, a recycling effort that transforms retired RAF Tornado components into powdered metal for 3D printing. This process was used to manufacture new parts for the Orpheus small engine concept, a key element of the UK’s Future Combat Air System (FCAS) programme.

Tornado components, including low-pressure compressor blades, were atomised into feedstock and used to 3D print a nose cone and compressor blades. Rolls-Royce installed the printed nose cone on an Orpheus test engine and successfully ran it under operational conditions.

Andrew Eady, Rolls-Royce VP FCAS Sustainability, says: “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 was led by Defence Equipment and Support’s Defence Recycling & Disposals Team (DRDT) in collaboration with the MOD FCAS team, Rolls-Royce and Additive Manufacturing Solutions Limited (AMS). It was funded by UK Strategic Command’s Defence Support Organisation.

A Digital Product Passport was also developed to track material provenance and lifecycle data, potentially improving resource management and protecting against counterfeit materials.

The project involved more than 80 participants, including DRDT commercial graduates and Rolls-Royce apprentices. It was recently recognised with a CDLS Commendation from the MOD’s Chief of Defence Logistics and Support.