The UK Ministry of Defence (MoD) has announced a new aircraft recycling initiative that repurposes components from retired RAF Tornado strike fighters for use in the next-generation Tempest combat jet. Known as Tornado 2 Tempest, the program is a collaboration between the MoD’s Defence Equipment and Support’s Defence Recycling and Disposals Team, the Future Combat Air System (FCAS) team, Rolls-Royce, and Additive Manufacturing Solutions (AMS) in Lancashire.

According to the MoD, the initiative is intended to enhance sustainability in defense manufacturing and could provide benefits such as reducing costs, repurposing surplus materials, and maintaining access to strategic resources for future aircraft production.

The project involves processing surplus Tornado components, including titanium compressor blades and structural elements, into high-quality metal powders. These materials, known as “feedstock,” are then remanufactured using additive manufacturing (3D printing) to create components for the Tempest program.

As part of a test, Rolls-Royce produced and installed a 3D-printed nose cone and compressor blades in the Orpheus test engine, an experimental Rolls-Royce powerplant developed under the FCAS program. The MoD reported that the recycled parts passed all safety and performance checks, demonstrating their potential viability for the Tempest’s propulsion system.

Maria Eagle, UK Minister for Defence Procurement and Industry, described the program as an effort to support cost savings and resource efficiency in the military sector.

“By working with key industry partners, we can save costs, reduce dependence on global supply chains, and ensure our Armed Forces have the best equipment,” Eagle said in a statement.

The Tempest fighter, developed under the Team Tempest consortium—which includes the MoD, BAE Systems, Rolls-Royce, Leonardo, and MBDA UK—is scheduled to replace the Eurofighter Typhoon starting in 2035. The aircraft will feature stealth technology, artificial intelligence, advanced sensors, and next-generation weapons systems designed for future combat requirements, according to the MoD.

Officials involved in the Tornado 2 Tempest initiative say that additive manufacturing could play a role in producing lighter, stronger, and more efficient components than those made using traditional methods. The MoD has suggested that using recycled materials could contribute to long-term cost savings and sustainability goals.

The Tornado 2 Tempest initiative is part of broader efforts within the Global Combat Air Programme (GCAP)—a partnership between the UK, Italy, and Japan aimed at developing a next-generation stealth fighter. Officials working on the program say that integrating 3D-printed, recycled components into GCAP aircraft could influence future combat aircraft production on a global scale.

While the long-term impact of the Tornado 2 Tempest program remains unclear, officials involved in the initiative say that early test results have been promising.