RAF's next-gen Tempest stealth fighter made from recycled old-gen Tornados

Individual parts from retired combat aircraft have been ground down and 3D-printed into new components suitable for the RAF's next-generation Tempest.

The recycling project has seen parts from old Tornado aircraft turned into powdered metal and used to make new components that will be suitable for the stealth jet.

Many of the Ministry of Defence's surplus assets contain strategic metals, including high-quality steel, aluminium and titanium.

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Members of the Tornado 2 Tempest recycling project team have been identifying whether some of these components could be atomised into powders for additive manufacturing to make new parts.

The development could save money and reduce the UK's reliance on global supply chains of critical and high-value metals.

Powdered metal can also be used to produce components that are lighter, stronger and longer lasting than those made through traditional forging techniques.

Tornado parts containing titanium were selected, including jet engine compressor blades from a low-pressure air compressor.

They were cleaned, successfully atomised and recycled into a 3D-printed nose cone and compressor blades.

The work was carried out by Additive Manufacturing Solutions Limited for Orpheu – Rolls-Royce's small engine concept that is part of the MOD's Future Combat Air System programme that will deliver Tempest.

The nose cone was fitted onto an Orpheus test engine and passed suitability and safety checks, demonstrating the technique has potential use in the sixth-generation jet.

Defence Procurement Minister Maria Eagle said: "The Tornado 2 Tempest project highlights the creativity, ingenuity and innovation defence employs in our approach to national security.

"By working with key industry partners, we can deliver savings, reduce reliance on global supply chains and ensure our Armed Forces have the very best kit to keep our country safe."

Tempest is a collaborative project involving Britain, Italy and Japan.

Engineers from across BAE Systems, Leonardo and Mitsubishi Heavy Industries are working together under a collaboration agreement on the design and development of the aircraft.

BAE Systems says the Tempest, which is set to be in service in 2035, will be one of the world's most advanced, interoperable, adaptable and connected fighter jets in service.