Recycled Titanium Helicopter Hinges
QinetiQ's Helicopter Uses a Recycled Titanium Structural Hinge
Kanesa D — February 20, 2026
QinetiQ has successfully flown a 3D-printed titanium component on its A109S helicopter at MOD Boscombe Down, Wiltshire. The additively manufactured hinge, part of an Air Data Boom for the ETPS flight test training school, was designed and integrated by QinetiQ and produced by AMS Ltd using recycled titanium from a decommissioned aircraft.
AMS Ltd’s proprietary recycling process converts scrap metal into high-quality powder suitable for additive manufacturing, achieving 97% material efficiency and significantly reducing waste. The method also lowers carbon emissions by 93.5% compared with traditional manufacturing, making it particularly valuable for high-cost, hard-to-source metals like titanium, which is prized in defence and aerospace for its strength, light weight, and corrosion resistance.
For businesses in aerospace and defence, this demonstrates how combining additive manufacturing with recycled materials can reduce costs, secure supply chains, and cut environmental impact—critical factors given rising global demand for aerospace-grade titanium and the reliance on limited suppliers in regions such as China and Russia.
