Printing the future of aviation parts manufacturing

The component flown was a hinge, forming part of an Air Data Boom, attached to a QinetiQ-owned A109S helicopter, which is being developed for ETPS flight test training.

QinetiQ designed and integrated the hinge, while AMS manufactured it using titanium recovered from a decommissioned aircraft.

AMS’ proprietary process recycles scrap metal and creates powder that meets the quality requirements for printing a new product, achieving 97 per cent efficiency and minimising material loss; particularly valuable for high-cost, hard-to-source metals like titanium.

The process also uses 93.5 per cent less CO2e, offering a step change in environmental impact compared to traditional supply chains.

“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,” according to QinetiQ managing director air Simon Galt.

“Not only are we helping to strengthen UK supply chains, but we are also leading the rest of the world in the very latest 3D printing technology.”

Titanium is commonly used in defence platforms, due to its high strength-to-weight ratio and its resistance to corrosion.

Global demand for the material has increased due to urbanisation and infrastructure growth, with China and Russia as the largest suppliers of aerospace-grade titanium globally.

The approach adopted by AMS and QinetiQ could reduce the UK’s dependence on imported titanium, with AMS estimating that the UK could become self-sufficient if all the titanium held in scrap aircraft were extracted for recycling.

“AMS has tirelessly built momentum and expertise within the additive powder market, with a sharp focus on providing recycled feedstocks,” according to AMS director and chief executive officer Rob Higham.

“This milestone reflects the dedication of our team and QinetiQ’s commitment to a more resilient and sustainable future.”

The innovation in 3D printing technology followed the installation of an in-house-manufactured 3D-printed component on an operational Royal Air Force Typhoon fighter jet in August last year.

During that fitting, a temporary replacement part for the pylon assembly that connects weapons systems to the aircraft’s wing was successfully installed onto a 29 Squadron Typhoon at RAF Coningsby.

“This technology offers enormous potential to maintain our aircraft faster than ever before. The 71 Squadron team has been exceptional – their expertise and collaboration made this milestone possible,” according to Wing Commander Gemma Lonsdale, Officer Commanding Air Wing Engineering at RAF Coningsby.

The repair was manufactured at the Hilda B. Hewitt Centre for Innovation, by specialists from No 71 Inspection & Repair Squadron and then installed by 29 Squadron engineers.

As part of the process, engineers precision-scanned the damaged component and shared the data with both the original manufacturer and 71 Squadron. While the manufacturer developed a permanent replacement, 71 Squadron designed and printed an intermediate solution.

The development of 3D printing technology in aircraft is expected to rapidly increase in the immediate future as producers seek lighter and more durable materials.

Additive technology is attractive to aircraft manufacturers because of component weight benefits, reduced material consumption, reinforcement with carbon fibre, low flammability and toxicity, and mechanical and thermal resistance.

“3D printer manufacturers have been closely observing the needs of the aircraft industry to propose customised solutions to cater for the growing needs of users,” according to 3DGence sales manager Sebastian Pietruszewski.