Article Summary: The UK’s Tornado 2 Tempest project is pioneering a new approach to fighter jet manufacturing by recycling Cold War-era Tornado aircraft into materials for the next-generation Tempest.
Key Points #1 – Using additive manufacturing, high-value metals like titanium are repurposed into 3D-printed components for Rolls-Royce jet engines, reducing costs and reliance on global supply chains.
Key Points #2 – This breakthrough could reshape aerospace production while fueling job growth in the UK. As Germany phases out its Tornado fleet for F-35s, could NATO allies benefit from this innovative recycling approach? If successful, Tornado 2 Tempest could set a new standard for sustainable military aircraft development.
UK Recycles Tornado Fighter Jets to Build Next-Gen Tempest Aircraft
What happens to old ships when they’ve reached the end of their service lives? They’re scrapped — recycled for other purposes, and the material is reused for different ships and other applications. Well, now, the same might happen on a similar scale in the United Kingdom for older Cold War-era fighter jets to provide useful material for new, sixth-generation aircraft thanks to additive manufacturing technology.
The project, dubbed “Tornado 2 Tempest” is apparently off to a flying start. The goal is to conserve useful bits of titanium and other important metals from the old Tornados and use them to build state-of-the-art aircraft for ultimate financial saving.
“The development could save taxpayer money, reduce the UK’s reliance on global supply chains of critical and high value metals and produce components that are lighter, stronger, and longer lasting than those made through traditional forging techniques,” the Royal Air Force explains.
But it is not just high-end exotic metals like titanium that could be used either. “Many of the Ministry of Defence’s surplus assets contain strategic metals, including high quality steel, aluminium, and titanium, and the Tornado 2 Tempest project team have been identifying whether some of these components could be atomised into powders – known as “feedstock” – for additive manufacturing to make new parts.”
The materials wouldn’t necessarily be used for components like airframe skins, wings, or other parts but could see an application within modern jet engines. And so far, at least, it’s been successful.
“Tornado parts containing titanium, including jet engine compressor blades from a low-pressure air compressor, were selected. They were cleaned, successfully atomised and recycled into a 3D printed nose cone and compressor blades by Additive Manufacturing Solutions Limited (AMS) for Orpheus – Rolls-Royce’s small engine concept that is part of the MOD’s Future Combat Air System (FCAS) programme delivering Tempest,” the Royal Air Force explained.
“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.”
Jobs, Jobs, Jobs
The Royal Air Force seems to be pitching the production strategy as a way to fuel job growth in the United Kingdom. “The initiative,” the Air Force said, “also led to the creation of three jobs and sustained two at Small Medium-Sized Enterprise (SME), AMS. The business now expects to create 25 new jobs by offering the innovation to other suppliers.”
“A team of more than 80 people participated in the project, including DRDT’s commercial graduates and Rolls-Royce graduate apprentices, combining current skills and innovative technologies to deliver and maintain future capabilities.”
The German Connection
One area of potential growth for additive manufacturing strategy, for this project at least, could be in Germany, one of the few remaining operators of the aged aircraft — though one with an outsized importance within the Luftwaffe and the NATO Alliance.
Under the auspices of NATO, German-piloted Panvia Tornados are equipped to deliver American nuclear weapons in the event of nuclear war involving NATO in Europe. But, given the platform’s age, they’re ripe for replacement.
In March of 2022, as part of Chancellor Olaf Scholz’ Zeitenwende or “turning point” speech, the Bundeswehr was given access to a €100 billion one-off fund to improve war readiness. And, in March of 2022, Berlin announced they would acquire 35 F-35A stealth fighters to replace their Panavia Tornados.
Though additive manufacturing in the case of aerospace recycling has not yet reached maturity, there is an argument to be made that the technology could benefit the German Air Force and, consequently, NATO security.
Tempest Fighter Artist Renderings:
Tempest Fighter 6th Generation.
Image of the UK’s concept model for the next generation jet fighter “Tempest”, which was unveiled by Defence Secretary, at Farnborough International Air Show back in 2018.
Tempest 6th-Generation Fighter from BAE Systems.
Tempest UK-based Sixth Generation Fighter. Image Credit: BAE Screenshot.
BAE Systems artist image of Tempest Stealth Fighter. Image Credit: BAE.
Tempest. Image Credit: Industry handout.
About the Author: Caleb Larson
Caleb Larson is an American multiformat journalist based in Berlin, Germany. His work covers the intersection of conflict and society, focusing on American foreign policy and European security. He has reported from Germany, Russia, and the United States. Most recently, he covered the war in Ukraine, reporting extensively on the war’s shifting battle lines from Donbas and writing on the war’s civilian and humanitarian toll. Previously, he worked as a Defense Reporter for POLITICO Europe. You can follow his latest work on X.
