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.

Advertisement

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)