Defense & Military
UK Flies Helicopter with Structural Parts from Recycled Titanium
QinetiQ and AMS Ltd. flew a helicopter using 3D-printed structural parts made entirely from recycled titanium, reducing emissions and supply risks.
This article is based on an official press release from QinetiQ and Additive Manufacturing Solutions (AMS) Ltd.
In a significant breakthrough for sustainable aerospace Manufacturing and Supply-Chain independence, British defense technology company QinetiQ, in partnership with Additive Manufacturing Solutions (AMS) Ltd., has successfully flown a helicopter equipped with a structural component 3D-printed entirely from recycled titanium. The flight, conducted at MoD Boscombe Down in Wiltshire, marks what the companies believe to be a world first for a structural aircraft part manufactured using recycled titanium powder.
The project addresses two critical challenges facing the modern aerospace industry: the urgent need to decarbonize manufacturing and the strategic necessity of securing raw material supply chains against geopolitical instability. According to the announcement made on February 17, 2026, the new manufacturing process reduces carbon emissions by over 90% compared to traditional methods while offering a viable path to end reliance on titanium imports from nations such as Russia and China.
The test flight utilized a QinetiQ-owned Agusta A109S helicopter. The specific component tested was a structural hinge used on the aircraft’s Air Data Boom, a critical device responsible for measuring airspeed and altitude. While 3D printing (additive manufacturing) has been used in aerospace for some time, the use of high-grade titanium powder derived entirely from scrap metal for a structural application represents a major leap forward.
QinetiQ led the design, integration, and flight testing phases of the project, while AMS Ltd., an SME based in Burscough, Lancashire, handled the material processing and manufacturing. The initiative builds upon the R2AM2 project (Recycling and Reuse of Aerospace Materials for Additive Manufacturing), which received funding from Innovate UK.
The core innovation driving this success is the ability to convert “swarf”, the scrap metal debris generated during machining, and retired aircraft parts into high-quality feedstock for 3D printers. AMS Ltd. employs a proprietary process to recycle this scrap into powder suitable for Laser Powder Bed Fusion (LPBF).
According to technical data released by the partners, this process achieves 97% material efficiency, meaning nearly all scrap metal input is successfully converted into usable new material. Furthermore, the environmental benefits are substantial. The recycled titanium process reportedly reduces carbon dioxide equivalent (CO2e) emissions by 93.5% compared to the energy-intensive mining and refining required for “virgin” titanium.
“AMS has tirelessly built momentum and expertise within the additive powder market, with a sharp focus on providing recycled feedstocks. This milestone reflects the dedication of our team and QinetiQ’s commitment to a more resilient and sustainable future.”
, Rob Higham, CEO, AMS Ltd.
Beyond the environmental credentials, this technology offers a strategic lifeline for the UK defense and aerospace sectors. Titanium is a notorious bottleneck in Western supply chains, with Russia (via VSMPO-AVISMA) and China historically dominating the global market for titanium sponge and forged products.
By validating a process that turns domestic scrap into flight-critical components, the UK could theoretically become self-sufficient in aerospace-grade titanium. AMS Ltd. estimates that by systematically recycling material from retired aircraft and manufacturing waste, the UK could eliminate its need for raw titanium imports entirely.
Simon Galt, Managing Director Air at QinetiQ, emphasized the dual benefits of the project in a press statement:
“Our testing and engineering expertise is helping to prove the technology which will reduce the UK’s dependency on other nations for aerospace grade titanium. Not only are we helping to strengthen UK supply chains, we are also leading the rest of the world in the very latest 3D printing technology.”
, Simon Galt, Managing Director Air, QinetiQ
The successful flight of the Agusta A109S with recycled parts is more than a technical curiosity; it is a proof-of-concept for the “circular economy” in defense. Historically, military and aerospace equipment has been viewed as a sunk cost at the end of its life. This project suggests that retired airframes should instead be viewed as strategic stockpiles of high-grade raw materials.
We note that this development aligns with broader industry movements, such as the DECSAM project (Digitally Enabled Competitive & Sustainable Additive Manufacturing). Led by Airbus and involving partners like the University of Sheffield and AMS Ltd., this £38 million initiative aims to scale up sustainable additive manufacturing by 2028. The involvement of major academic and industrial players suggests that the technology demonstrated by QinetiQ is moving rapidly from research to industrial application.
If the UK can scale this recycling capability, it will insulate its defense industry from the price volatility and political leverage associated with foreign titanium suppliers. However, the challenge will now shift to Certification. Proving that a recycled part works on a test flight is the first step; proving to regulators that recycled powder maintains consistent fatigue properties across thousands of flight hours will be the hurdle for mass adoption.
What is the primary benefit of using recycled titanium? Is the recycled material as strong as new titanium? Who funded this research? Sources: QinetiQ, University of Sheffield (Context)
UK Achieves World First: Helicopters Flies with Structural Parts Made from Recycled Titanium
The Milestone Flight
Engineering a Circular Economy
Strategic Independence and Supply Chain Security
AirPro News Analysis
Frequently Asked Questions
The primary benefits are twofold: environmental and strategic. It reduces carbon emissions by approximately 93.5% compared to mining new titanium, and it allows the UK to produce high-grade materials domestically, reducing reliance on imports from Russia and China.
Yes. The testing conducted by QinetiQ and AMS Ltd. indicates that the recycled powder meets the rigorous quality standards required for aerospace structural components, proving chemically and mechanically equivalent to virgin titanium.
The work builds on the R2AM2 project, which was funded by Innovate UK, the United Kingdom’s innovation agency.
Photo Credit: QinetiQ
Defense & Military
Airbus Unveils Dual Rotorcraft Concepts for NATO Next Gen Capability
Airbus presents two rotorcraft concepts for NATO’s Next Generation Rotorcraft Capability, focusing on speed and affordability for future military missions.
Airbus Helicopters has officially presented its vision for the future of military vertical lift, unveiling two distinct rotorcraft concepts designed to meet the requirements of the NATO Next Generation Rotorcraft Capability (NGRC) study. Announced on February 23, 2026, in Marignane, France, the proposal diverges from a “one-size-fits-all” approach by offering both a high-speed compound concept and a high-performance conventional Helicopters.
The initiative is part of a broader NATO effort to identify replacements for medium-lift multi-role helicopters currently in service, such as the NH90 and AW101, with a targeted entry into service in the late 2030s. Airbus has partnered with major defense industry players, including RTX businesses Collins Aerospace and Raytheon, as well as MBDA, to develop these concepts.
According to the company’s official statement, the Airbus proposal prioritizes fleet complementarity. By developing two separate airframes that share a common digital backbone, Airbus aims to provide NATO nations with flexibility regarding cost and mission profile.
The first concept focuses on speed and range, leveraging the aerodynamic configuration validated by Airbus’s X3 and Racer demonstrators. This design features added wings and lateral propellers, which the Manufacturers states will offer significantly higher speeds than conventional designs. Beyond raw speed, the configuration is designed to extend the flight envelope, allowing for rapid acceleration, deceleration, and enhanced climb and descent capabilities, traits critical for combat search and rescue (CSAR) or medical evacuation (MEDEVAC) missions.
The second concept is a conventional helicopter designed for standard utility roles where affordability and lift capacity may take precedence over extreme speed. While specific airframe details were not disclosed in the press release, the design philosophy emphasizes simplicity in manufacturing and maintenance to ensure long-term affordability.
Bruno Even, CEO of Airbus Helicopters, highlighted the necessity of this mixed approach in a statement:
“We want to ensure that Europe is in a position to propose a platform that will best fit our military partners’ needs in terms of affordability, operational efficiency and maximum availability for both the conventional helicopter and for the high speed rotorcraft. These two concepts are a basis to further exchange with our military partners on their vision and need for future military operations.”
A core tenet of the Airbus proposal is the use of a Modular Open System Architecture (MOSA). This approach allows for the rapid integration of new technologies and ensures that both the high-speed and conventional platforms can share systems, training simulations, and maintenance tools.
The collaboration with RTX and MBDA suggests a focus on advanced connectivity and lethality. According to Airbus, the concepts will feature: The NATO Support and Procurement Agency (NSPA) originally awarded the contract for this concept study in July 2024. The study challenges participants to design, develop, and deliver a medium multi-role helicopter capable of meeting future battlefield threats.
The Strategic Advantage of Hedging
By proposing two distinct aircraft, Airbus appears to be differentiating its strategy from competitors who are largely betting on single, radical architectures. While competitors like Sikorsky (Lockheed Martin) and Leonardo are advancing coaxial and tilt-rotor technologies respectively, Airbus is offering a “menu” option. This allows NATO members with tighter budgets to opt for the conventional, lower-risk platform, while those requiring rapid reaction capabilities can select the high-speed variant.
This dual approach also mitigates technical risk. While the Racer demonstrator has proven the compound wing-and-propeller configuration in flight tests, it remains a more complex solution than a standard rotorcraft. Offering a conventional alternative ensures that Airbus remains a viable contender even if NATO requirements shift back toward cost-efficiency over raw speed.
What is the NATO NGRC project? Who are Airbus’s partners on this project? Is the high-speed concept a new design?
Airbus Unveils Dual Rotorcraft Concepts for NATO’s Next Generation Capability
A Dual-Platform Strategy
The High-Speed Compound Concept
The Conventional High-Performance Helicopter
Technological Foundation and Partnerships
AirPro News Analysis
Frequently Asked Questions
The Next Generation Rotorcraft Capability (NGRC) is a NATO initiative to develop a new class of medium-lift helicopters to replace aging fleets starting in the 2035–2040 timeframe.
Airbus is collaborating with RTX (specifically Collins Aerospace and Raytheon) for avionics and systems, and MBDA for weapons integration.
The military concept is a direct evolution of Airbus’s civilian demonstrators, the X3 and the Racer. The Racer recently completed flight evaluations with military pilots to validate the benefits of its wing-and-propeller configuration.
Sources
Photo Credit: Airbus
Defense & Military
BAE Systems Demonstrates Modular Electromagnetic Attack for UAVs
BAE Systems tested a scalable electromagnetic attack system for Group 4/5 UAVs, supporting distributed electronic warfare and complementing USAF EA-37B aircraft.
This article is based on an official press release from BAE Systems.
BAE Systems has successfully demonstrated a new modular electromagnetic attack (EA) system during recent test events conducted in collaboration with the U.S. Air Force. The demonstrations focused on the company’s ability to scale down high-performance electronic warfare hardware for use on smaller platforms, specifically unmanned aerial vehicles (UAVs).
According to the company, the tests involved flying a prototype system housed in a weapon pod on an aircraft acting as a surrogate for Group 4 or Group 5 UAVs. The events highlighted the system’s capacity to execute complex counter-C5ISRT (command, control, communications, computing, cyber, intelligence, surveillance, reconnaissance, and targeting) missions using a compact, modular architecture.
The core of the demonstration was a modular version of BAE Systems’ existing high-power airborne EA weapon systems. By re-engineering these “exquisite” capabilities into a smaller form factor, the company aims to enable a network of distributed electromagnetic effects across the battlefield. This approach allows smaller, more affordable platforms to contribute to electronic warfare missions that were previously the domain of large, specialized aircraft.
In a press statement, BAE Systems noted that the system runs proven software capable of neutralizing adversary air defenses and disrupting their battlespace coordination. Notably, the architecture supports third-party software applications, reinforcing the U.S. Department of Defense’s push for open systems that can be rapidly updated with new techniques.
“We’re showing the armed services that we can scale down our high-performance EA hardware and repurpose it for smaller nodes on the network. We’re innovating to deliver a cost-efficient mix of exquisite and affordable capabilities that work together to deliver a discriminating effect on the battlespace.”
, Rory Duddy, Program Director for Modular Electromagnetic Attack at BAE Systems
The demonstrated technology is designed to operate independently or in conjunction with high-end assets. BAE Systems explicitly positioned the modular system as a complement to the U.S. Air Force’s EA-37B electromagnetic attack aircraft. While the EA-37B provides full-spectrum jamming power, smaller modular systems deployed on drones could penetrate contested airspace to deliver targeted effects at closer range.
The “small-scale systems” are intended to generate “mass electromagnetic effects,” effectively overwhelming adversary sensors through volume and distribution rather than relying solely on a single high-power source. This strategy aligns with broader military efforts to disaggregate capabilities, making it harder for adversaries to target a single point of failure. The successful testing of a pod-mounted EA system for Group 4/5 UAVs is a significant step toward the U.S. Air Force’s vision of Collaborative Combat Aircraft (CCA). As the service seeks to pair manned fighters with autonomous drones, electronic warfare is a primary mission set for these uncrewed wingmen. By proving that high-end jamming capabilities can be packaged into a modular weapon pod, BAE Systems is positioning itself to supply the electronic “teeth” for future drone fleets. This modularity also suggests a potential for rapid retrofitting, allowing legacy drones to assume electronic attack roles without extensive airframe modifications.
Sources: BAE Systems (PR Newswire)
BAE Systems Demonstrates Scalable Electromagnetic Attack Capabilities for UAVs
Modular Architecture for Distributed Warfare
Complementing the EA-37B
AirPro News Analysis
Frequently Asked Questions
Photo Credit: BAE Systems
Defense & Military
Saudi Ministry of Interior Awards Aerial Contract to Thrush Aircraft and AAT
Saudi Arabia’s Ministry of Interior awards contract to Thrush Aircraft and AAT to enhance firefighting and border security with localized support.
This article summarizes reporting by AerialFire Magazine.
On February 23, 2026, the Kingdom of Saudi Arabia’s Ministry of Interior (MOI) awarded a significant contract to Albany, Georgia-based Thrush Aircraft and its local strategic partner, Advanced Aircraft Technology (AAT). According to a report by AerialFire Magazine, the agreement is designed to enhance the Kingdom’s aerial capabilities, specifically targeting firefighting and border security operations, while adhering to the localization mandates of Vision 2030.
The deal positions Thrush Aircraft as the prime manufacturer for the fleet, while AAT will serve as the in-country provider for logistics, maintenance, and training. This partnership underscores a growing trend of integrating international manufacturing expertise with domestic support infrastructure to ensure long-term operational readiness.
The collaboration between the US manufacturer and the Saudi service provider covers a “tail-to-tooth” support structure. While specific fleet numbers were not disclosed in the initial announcement, the partnership focuses on delivering specialized aerial application aircraft suited for the region’s unique environmental challenges.
Industry observers note that the contract likely involves the Thrush 710P Fire Bird, a single-engine air tanker designed for rapid initial attack on wildfires. With a 710-gallon hopper and advanced avionics, this model is capable of operating from remote, unimproved airstrips, making it a strategic asset for the General Directorate of Civil Defense.
Additionally, the Thrush 510G model may be utilized for surveillance and border patrol missions. These aircraft offer a cost-effective alternative to traditional rotorcraft, providing long loiter times essential for monitoring the Kingdom’s extensive borders.
As the local strategic partner, AAT is tasked with ensuring that the economic benefits of the contract remain within Saudi Arabia. Headquartered in Riyadh, AAT is licensed by the General Authority for Military Industries (GAMI) and will handle:
“AAT has previously stated its mission is to diversify Aviation services by localizing them in KSA utilizing our vast relationships with Aviation local and international partners.”
, Background information via AerialFire Magazine
This contract award follows significant developments in Saudi Arabia’s defense industrial base. In May 2025, AAT entered a partnership with Burkhan World Investments (BWI) to establish “BWI Nexus,” a defense innovation hub backed by a reported $5 billion fund. This infrastructure is expected to support the lifecycle management of the new Thrush fleet, positioning the Kingdom as a regional hub for light attack and aerial firefighting aircraft maintenance.
Localization as a Priority Operational Shift Who are the primary contractors? What aircraft are likely included? What is the role of AAT?
Saudi Ministry of Interior Awards Aerial Contract to Thrush Aircraft and AAT
Contract Scope and Fleet Capabilities
Aircraft Specifications
Role of Advanced Aircraft Technology (AAT)
Strategic Industrial Context
AirPro News Analysis
This agreement is a clear execution of Saudi Arabia’s Vision 2030, which aims to localize 50% of defense spending. By mandating a local partner like AAT for the sustainment phase, the Ministry of Interior ensures that technical expertise is transferred to Saudi nationals and that maintenance expenditures circulate within the domestic economy rather than flowing exclusively to foreign contractors.
From an operational standpoint, the acquisition of fixed-wing single-engine air tankers represents a shift toward more agile, rapid-response firefighting. Unlike heavy water bombers that require major airport infrastructure, the Thrush platforms can deploy from smaller regional airfields. This capability allows for faster reaction times to wildfires, potentially containing incidents before they escalate into unmanageable blazes.
Frequently Asked Questions
Thrush Aircraft (USA) is the aircraft manufacturer, and Advanced Aircraft Technology (Saudi Arabia) is the local partner responsible for support and maintenance.
The deal is expected to utilize the Thrush 710P Fire Bird for firefighting and potentially the 510G for surveillance and border security.
AAT will provide in-country support, including pilot training, supply chain management, and maintenance, repair, and overhaul (MRO) services.
Sources
Photo Credit: Agricultural Aviation Magazine
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