QinetiQ pioneers 3-D printed helicopter from recycled titanium

QinetiQ has completed a flight test of an aircraft fitted with a structural component 3D printed from recycled titanium. The UK global defence and security company describes the milestone as a world first.

The component was a hinge forming part of an air data boom assembly. Engineers designed and integrated the part for an aircraft at the Empire Test Pilots’ School in Wiltshire.

The flight took place using a company-owned Agusta A109S helicopter. QinetiQ’s Flight Test Organisation conducted the trial.

97% material efficiency

Additive Manufacturing Solutions (AMS) manufactured the hinge, processing titanium feedstock recovered from a decommissioned aircraft. It used a proprietary method to convert scrap titanium into powder suitable for additive manufacturing.

The company reports 97% material efficiency. It also claims a 93.5% reduction in carbon dioxide equivalent emissions compared with conventional supply chains.

The additive process, post-processing steps or certification pathway has not been revealed. However, the successful flight provides operational validation of recycled titanium in a structural aerospace application.

Boosting UK supply chains

The UK aerospace and defence sectors rely heavily on imported raw materials. Recycling titanium from retired aircraft creates a domestic source of aerospace-grade feedstock. AMS argues that systematic extraction from UK-held scrap aircraft could support national self-sufficiency. The company has not disclosed projected annual volumes.

Simon Galt, Managing Director Air at QinetiQ, says the project ‘strengthens domestic supply chains’ and the technology reduces dependence on overseas sources of titanium while advancing 3-D printing capability.

Consortium effort

AMS is also part of the Digitally Enabled Competitive & Sustainable Additive Manufacturing project, a EUR 32.5 million, four-year programme, led by Airbus. It aims to accelerate cost-effective, sustainable production of flight-ready components. The project concludes in 2028.