New fighter jet components can be 3D printed
Rolls Royce
A groundbreaking innovation in aircraft manufacturing is taking place in the UK’s Royal Air Force (RAF), where fighter jets from the 1970s are being repurposed through 3D printing technology. This revolutionary approach, spearheaded by Robert Higham at Additive Manufacturing Solutions, not only enhances efficiency but also addresses environmental concerns and sourcing challenges faced by traditional manufacturing methods.
Higham’s team has developed a method to recycle essential materials like Ti64, a titanium alloy used in aircraft construction. By extracting these materials from decommissioned or damaged aircraft, such as the Panavia Tornado, the RAF can now utilize them to create components for next-generation fighter jets.
According to Higham, the process involves transforming old turbine blades into a fine powder through a specialized technique. This powder is then fed into 3D printers, where it is meticulously layered to form new components with precision and accuracy. The result is a sustainable and cost-effective solution that supports the RAF’s advancement in aviation technology.
One notable application of this innovative approach is the production of a nose cone for a prototype engine designed for the RAF’s upcoming fighter jet models. This engine, part of the Future Combat Air System (FCAS) developed by Rolls Royce, signifies a significant leap forward in aerospace engineering.
Higham emphasizes the importance of creating spherical particles from recycled components to ensure optimal 3D printing quality. By utilizing a process similar to the formation of hailstones, the recycled materials are transformed into a suitable powder for additive manufacturing.
Overall, this transformative method not only streamlines aircraft production but also exemplifies a sustainable and forward-thinking approach to aerospace engineering. As the RAF continues to embrace cutting-edge technologies, the future of aviation looks brighter than ever.
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