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.
UK Achieves World First: Helicopters Flies with Structural Parts Made from Recycled Titanium
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 Milestone Flight
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.
Engineering a Circular Economy
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.
Strategic Independence and Supply Chain Security
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
AirPro News Analysis
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.
Frequently Asked Questions
What is the primary benefit of using recycled titanium?
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.
Is the recycled material as strong as new titanium?
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.
Who funded this research?
The work builds on the R2AM2 project, which was funded by Innovate UK, the United Kingdom’s innovation agency.
Sources: QinetiQ, University of Sheffield (Context)
Photo Credit: QinetiQ
Defense & Military
NexTech Solutions Acquires BOOMSLANG Aerospace for UAS Defense
NexTech Solutions acquires BOOMSLANG Aerospace, adding UAS and Counter-UAS tech including the MONGOOSE system to its DoD portfolio.
NexTech Solutions (NTS) has finalized the acquisition of BOOMSLANG Aerospace, integrating new Unmanned Aerial Systems (UAS) and Counter-UAS (C-UAS) technologies into its defense-grade product portfolio to address emerging tactical airspace threats.
Announced on August 24, 2026, following a transaction close on August 7, 2026, the acquisition marks the fifth corporate purchase by NTS since receiving strategic backing from private equity firm Clairvest in 2023. According to the company’s press release, the move is designed to provide modular, mission-ready solutions for the U.S. Department of Defense (DoD) and other government agencies.
Integrating UAS and Counter-UAS capabilities
The acquisition brings BOOMSLANG’s proprietary hardware and software into the NTS ecosystem. Central to this integration is the MONGOOSE C-UAS system, alongside the broader BOOMSLANG UAS family of systems. These platforms will join existing NTS products such as MANTLE, VidTerra COMPASS, and JEFF-K to create a networked defense architecture.
NTS leadership emphasized the operational readiness of the newly acquired technology and its immediate applicability to current defense requirements.
“BOOMSLANG Aerospace has built exactly the kind of technology our customers are asking for: cutting-edge, mission-ready, and purpose-built for the current threat environment at the edge,” stated Joseph Paull, CEO of NexTech Solutions.
David Pollman, Director of Counter-UAS Operations at NTS, noted that BOOMSLANG’s approach aligns with the company’s strategy to build modular, requirements-driven C-UAS architectures for government clients.
Corporate growth and defense sector strategy
The BOOMSLANG acquisition reflects a sustained expansion strategy for NTS, which operates out of Tampa, Florida, and Northern Virginia, with the latest announcement originating from Huntsville, Alabama. The 2023 investment from Clairvest positioned NTS as a platform company for defense technology growth, facilitating five acquisitions over the subsequent three years.
BOOMSLANG Aerospace leadership indicated the merger will accelerate product deployment. Alan Cornett, President and Co-Founder of BOOMSLANG Aerospace, stated that the combined entity can move faster from concept to fielded capability for defense customers.
AirPro News analysis
We view this acquisition as a direct response to the rapidly evolving tactical requirements of the U.S. Department of Defense. The proliferation of inexpensive, commercially available drones in modern conflict zones has forced defense contractors to rapidly scale their C-UAS offerings. By acquiring an established player like BOOMSLANG rather than developing a system entirely in-house, NTS accelerates its time-to-market. The emphasis on modular and networked ecosystems suggests NTS is positioning itself to offer comprehensive, plug-and-play airspace awareness and defeat mechanisms rather than standalone hardware.
Sources: NexTech Solutions (via PR Newswire)
Photo Credit: Montage
Defense & Military
NSPA Issues RFP for NATO Next Generation Rotorcraft Program
NSPA formally launches the NGRC Concept Design RFP, with four manufacturers competing for a six-nation helicopter replacement program.
The NATO Support and Procurement Agency (NSPA) has formally issued a Request for Proposal for the Concept Design phase of the Next Generation Rotorcraft Capability program, advancing a six-nation effort to replace aging medium multi-role Helicopters fleets.
Announced in a press release on August 10, 2026, the procurement targets a service entry between 2035 and 2040. The NSPA is managing the process on behalf of Canada, France, Germany, Italy, the Netherlands, and the United Kingdom. Four pre-qualified Manufacturers will compete in this phase: Airbus Helicopters, Leonardo Helicopters, The Boeing Company, and Sikorsky.
Advancing the concept design phase
The Request for Proposal (RFP) officially opened on July 31, 2026, and requires the four bidders to submit their concept design proposals by August 31, 2027, at 12:00 Paris Time. Under the procurement guidelines, each manufacturer can propose a maximum of two concept design solutions.
Maxime Martinez, Principal Procurement Officer for the Next Generation Rotorcraft Capability (NGRC) Programme at NSPA, confirmed the launch of the new phase.
I am pleased to announce that the NATO Support and Procurement Agency (NSPA) has launched the next phase of the Next Generation Rotorcraft Capability (NGRC) Programme: a formal Request for Proposals (RFP) to qualified bidders linked to the competition for the Concept Design phase of NGRC.
The NSPA is utilizing a procurement mechanism called Acquisition by Qualified Options. This framework allows the participating nations to evaluate digital trials within an in-house modeling and simulation environment before committing to physical prototypes. The agency plans to complete the bid evaluation process by the end of 2027, at which point it will deliver an evaluation summary report to the participating nations.
Industry positioning and proposals
The four pre-qualified bidders, selected following a Pre-Qualification Assessment that closed in October 2025, have already begun positioning their offerings for the multi-national replacement program.
In February 2026, Airbus Helicopters revealed two distinct concepts for the NGRC study. The European manufacturer is developing both a high-performance conventional helicopter and a high-speed compound rotorcraft that leverages technology from its Racer demonstrator program. Sikorsky, a Lockheed Martin company, announced in July 2026 that it would establish helicopter production facilities in Europe if the partner nations select its proposal.
The NSPA is encouraging broader industry participation through the primary bidders rather than direct submissions. Martinez stated that potential suppliers, technology providers, and industrial partners should engage directly with Airbus Helicopters, The Boeing Company, Leonardo Helicopters, or Sikorsky to contribute to the program.
AirPro News analysis
We view the NSPA decision to utilize the Acquisition by Qualified Options mechanism as a critical step in mitigating the technical and financial risks historically associated with clean-sheet rotorcraft development. By mandating digital trials in a simulated environment before advancing to physical prototypes, the participating nations can rigorously evaluate the aerodynamic and operational viability of complex designs, such as the compound concept proposed by Airbus Helicopters.
Sikorsky’s preemptive commitment to European production highlights the intense political and economic stakes of the NGRC program. With five European nations and Canada funding the development, North American bidders like Sikorsky and The Boeing Company will likely need to guarantee substantial industrial offsets and local manufacturing to remain competitive against indigenous European prime contractors like Airbus and Leonardo. The requirement for up to two concepts per bidder also provides the NSPA with a broad spectrum of conventional and advanced high-speed rotorcraft options to evaluate against the harmonized operational baseline.
Photo Credit: Airbus
Defense & Military
HAL and Safran Sign Aravalli Engine Co-Development Contract
HAL and Safran finalize the Aravalli engine contract via SAFHAL JV to power India’s IMRH and DBMRH helicopters by 2032-2033.
Hindustan Aeronautics Limited (HAL) and Safran Helicopter Engines have finalized a contract to co-develop the new-generation Aravalli engine, marking a definitive shift in Indian aerospace manufacturing from licensed production to indigenous propulsion design.
The agreement, signed on August 26, 2026, in Bengaluru, India, formalizes the design, development, manufacture, and lifecycle support of the engine through SAFHAL Helicopter Engines Pvt. Ltd. SAFHAL is a 50:50 joint venture between the two aerospace manufacturers. The Aravalli engine is slated to power India’s future 13-ton Indian Multi-Role Helicopter (IMRH) and its naval variant, the Deck-Based Multi-Role Helicopter (DBMRH).
Technical specifications and manufacturing
The Aravalli engine will operate in the 3,500 to 4,000 shaft horsepower (shp) class. Under the terms of the agreement, HAL will gain access to core engine technologies, including the high-pressure compressor, power turbine, and accessory gearbox. This technology transfer is designed to build domestic intellectual property and expertise in high-power engine design.
Manufacturing operations for the Aravalli program will be based at HAL’s facility in Tumakuru, Karnataka. Safran Helicopter Engines Chief Executive Officer Cédric Goubet noted the precedent set by the agreement in a press release issued by HAL.
“This is the first time Safran HE has taken up such a class of engine as co-development. The Aravalli engine programme represents a new chapter in the strategic relationship between France and India, combining the expertise of our teams to develop propulsion systems for future Indian rotorcraft.”
Development timeline and strategic shift
The final contract follows a multi-year negotiation and planning phase. HAL and Safran initially signed a Memorandum of Understanding for the project in July 2022, followed by detailed workshare discussions at Aero India in February 2023. The companies executed an airframer contract on August 30, 2024, to commence joint design work.
The design and development phase is targeted for completion between 2032 and 2033. Once operational, the IMRH platform is intended to replace the Indian Air Force’s aging fleet of Mil Mi-17 Helicopters. HAL Chairman and Managing Director Ravi K emphasized the domestic industrial impact of the program.
“The signing of this contract marks a significant step forward in India’s pursuit of self-reliance in aero-engine technologies. Through this collaborative programme with SAFHAL and Safran Helicopter Engines, we are creating a strong foundation for powering next-generation Indian helicopter platforms.”
AirPro News analysis
The Aravalli engine contract represents a critical maturation point for India’s defense aviation sector. Historically, Indian aerospace manufacturing has relied heavily on licensed production of foreign designs, which limits domestic engineering capability and intellectual property ownership. By securing a 50:50 co-development structure that includes core engine components like the high-pressure compressor and power turbine, we view this agreement as a foundational step toward true Propulsion independence for the Indian military. If the 2032 to 2033 development timeline holds, HAL will be positioned not just as an assembler, but as a primary original equipment Manufacturers (OEMs) for high-power rotorcraft engines.
Sources: Hindustan Aeronautics Limited
Photo Credit: Hindustan Aeronautics Limited
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