Milestone! UK Successfully Completes First Flight of Helicopter Component 3D Printed from Recycled Titanium

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March 20, 2026 News 8696

Recently, British defense giant QinetiQ announced a major breakthrough: a critical structural component for helicopters, 3D printed from recycled titanium alloy, has successfully completed its first flight test.

The test was conducted at the Ministry of Defence's Boscombe Down facility in Wiltshire, UK. The test piece was a 3D printed hinge mounted on a QinetiQ-owned A109S helicopter, which is currently being developed for the renowned Empire Test Pilots' School (ETPS).

This small printed part plays a crucial role—it serves as the attachment point for an air data probe, used to measure flight speed and angle of attack. Failure could cause the probe to break or lead to severe vibrations, directly impacting pilot training data.

The hinge was designed by QinetiQ and manufactured by Additive Manufacturing Solutions Limited (AMS Ltd.), with material sourced from recycled titanium from a scrapped aircraft. This flight demonstrates that through additive manufacturing, critical flight components can indeed be "turned from waste into valuable assets" and returned to service.

97% Utilization Rate, 93.5% Carbon Reduction

AMS holds a patented atomization process that converts recycled metal waste into printable powder, achieving a material utilization rate of up to 97% with virtually no waste. Even more impressive, this manufacturing method reduces CO2 emissions by 93.5% compared to traditional supply chains.

The Strategic Value of Titanium

Titanium alloy offers high strength, low density, and excellent corrosion resistance, making it the preferred material for aerospace applications. However, because it readily reacts with air at high temperatures, its production process is complex and costly, and aerospace-grade titanium primarily relies on imports from China and Russia.

AMS estimates that if the UK recycled all titanium from aircraft wrecks, it could theoretically achieve self-sufficiency. Simon Galt, Air Managing Director at QinetiQ, stated: "This technology will help the UK reduce its dependence on other countries for aerospace-grade titanium and move toward a more sustainable future."