In a groundbreaking move, the RAF’s next-generation Tempest fighter jet is being developed using parts from retired Tornado aircraft. This innovative recycling project aims to save costs, reduce reliance on global supply chains, and create more sustainable components for the Tempest, which is set to be in service by 2035.
The project involves the recycling of individual parts from retired Tornado jets, which are ground down into powdered metal and then used in additive manufacturing, also known as 3D printing. This method allows for the creation of new, high-performance components, including parts for the Tempest’s advanced stealth capabilities.
The UK Ministry of Defence’s Tornado 2 Tempest recycling initiative has focused on the valuable metals contained within surplus Tornado aircraft, such as titanium, high-quality steel, and aluminium. These metals are atomised into powder and used to create lightweight, durable components that are stronger and longer-lasting than those made through traditional forging techniques.
Among the recycled parts used in the project are titanium-filled jet engine compressor blades, which were originally part of a Tornado’s low-pressure air compressor. These parts have been successfully cleaned, atomised, and repurposed into critical components for the Tempest, including a 3D-printed nose cone and compressor blades.
The nose cone was fitted to an Orpheus test engine developed by Rolls-Royce for the MOD’s Future Combat Air System programme. After passing safety and suitability checks, it demonstrated the potential for this innovative recycling process to be used in the Tempest’s design and development.
Defence Procurement Minister Maria Eagle praised the project, stating that it showcases the “creativity, ingenuity and innovation” of the UK’s defence sector. She highlighted how the project not only provides cost savings but also reduces reliance on global supply chains for critical metals. By working with industry leaders like Rolls-Royce, BAE Systems, and Leonardo, the RAF aims to develop a fighter jet that is not only technologically advanced but also environmentally conscious.
Tempest is a collaborative project involving the UK, Italy, and Japan, with engineers from BAE Systems, Leonardo, and Mitsubishi Heavy Industries working together on its development. When it enters service in 2035, Tempest is expected to be one of the world’s most advanced, adaptable, and interconnected fighter jets.
