ErnieBilco
22 hours ago
Rolls-Royce turns retired British fighter jets into 3D-printed engine parts
Jet engine blades were turned into powder for 3D printing, with a nose cone successfully tested on an Orpheus engine by Rolls-Royce.
Updated: Feb 07, 2025 08:46 AM EST
2 days ago
Rolls-Royce turns retired British fighter jets into 3D-printed engine parts
RAF Tornado parts are recycled into additively manufactured jet engine components.
Rolls Royce
Rolls-Royce has pioneered a unique recycling effort, transforming the United Kingdom Royal Air Force’s (RAF) old aircraft parts into metal powder for additive manufacturing.
The Tornado 2 Tempest project repurposes retired RAF Tornado components into powdered metal, which is then used to 3D print parts for Rolls-Royce’s Orpheus small engine concept.
According to the firm, with Orpheus being part of the Future Combat Air System (FCAS) program, the project demonstrates that the technique has the potential to be used for the next-generation Tempest combat air platform.
“Tornado 2 Tempest is a bold, exciting, and innovative project and a demonstration of how excellent collaboration between the MOD, industry, and SME can deliver sustainable and technologically advanced solutions,” said Andrew Eady, Rolls-Royce VP FCAS Sustainability, in a statement.
Sustainable metal solutions
The Tornado 2 Tempest project has successfully repurposed retired RAF Tornado components into metal powder for additive manufacturing, demonstrating a sustainable approach to defense engineering.
Many surplus Ministry of Defence (MOD) assets, including broken or spare components, contain valuable metals like titanium, aluminum, and high-quality steel. The project team explored whether these materials could be atomized into powders, known as “feedstock,” for 3D printing.
Key components, such as jet engine compressor blades with high titanium content, were cleaned and converted into powder, resulting in a 3D-printed nose cone and compressor blades. Rolls-Royce installed the nose cone onto an Orpheus test engine, successfully running it under test conditions to confirm its safety and performance.
According to the firm, the initiative highlights the viability of recycling strategic metals, offering potential benefits for the UK defense industry by enhancing access to critical materials and reducing reliance on new raw resources.
The team also showcased a Digital Product Passport, tracking material provenance and lifecycle data. The innovation is suggested to enhance material allocation decisions and help prevent the use of counterfeit materials.
“Not only can this solution reduce the costs and burden of sourcing critical and high-value metals, but it can also produce components that are lighter, strong,er and longer lasting than those made through traditional forging techniques, thereby further enhancing the MOD’s overall sustainability and effectiveness,” said Thomas Powell, DRDT’s Strategic & Submarine Recycling Senior Commercial Manager, in a statement.
Efficient air propulsion
The Orpheus engine family is a cutting-edge twin-spool small engine designed for future combat air systems, offering scalability, adaptability, and high efficiency. Developed with a focus on rapid innovation, it features an advanced turbofan architecture, integrated electrical power generation, and ultra-low-cost components.
Utilizing Additive Layer Manufacturing (ALM), Orpheus reduces component complexity while enhancing performance, allowing for faster production and cost savings. The engine is designed for modularity, enabling rapid reconfiguration for different applications in military aviation. Digital design and manufacturing processes further streamline development, ensuring high precision and reduced time-to-market.
In just 18 months, Rolls-Royce designed, built, and tested the first twin-spool demonstrator engine, cutting traditional development time in half. The program’s agile approach and collaboration with over 30 UK-based SMEs have maximized efficiency and innovation.
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Rolls-Royce claims that with its advanced technology and rapid scalability, Orpheus is set to revolutionize future military propulsion systems.
ErnieBilco
2 weeks ago
Rolls-Royce has signed the biggest UK Ministry of Defence (MoD) contract in its history. The Unity contract stretches over eight years and brings together all elements of research and technology, design, manufacture and in-service support of the nuclear reactors that power the Royal Navy’s fleet of submarines. This contract between Rolls-Royce Submarines Ltd and the UK MoD, forms a single, harmonious capability portfolio.
Unity will enable improved focus on simplification and efficiency and better outcomes for the UK Royal Navy. It represents a significant undertaking and investment by the UK government and industry, providing thousands of highly skilled jobs across the country and an enduring commitment for the decades ahead. This is truly a national endeavour.
Rolls-Royce designs, builds and maintains all of the nuclear reactors that power the Royal Navy’s fleet of submarines. This eight-year Unity contract is worth circa £9 billion and will provide full support of the in-service UK Royal Navy submarine fleet throughout the period. It also includes continued support of the build and commission of Dreadnought Class submarines and the beginning of the previously announced SSN-AUKUS contracts.
The contract is the first of its kind awarded by the UK MoD and is the culmination of years of planning between Rolls-Royce and UK MoD, potentially creating a new way of doing business between Government and industry. It signposts the UK’s commitment to the continuous at sea nuclear deterrent and Rolls-Royce’s continuing dedication to the UK Royal Navy and the Defence Nuclear Enterprise.
With a long-term commitment across the Rolls-Royce Submarine programmes, Unity draws together current and upcoming work into one portfolio. It is designed to incentivise an even more collaborative working relationship between Rolls-Royce and the UK MoD.
ErnieBilco
3 months ago
This year, battery storage systems became the largest energy source in one of the biggest electricity grids in the world in California.
Data showed that the output of battery storage systems exceeded six gigawatts for around two hours – higher than the output of gas or hydroelectric power plants, nuclear power plants and renewable energies. In comparison, the record output of battery storage systems five years ago was just 120 megawatts, highlighting their increasing role in the energy transition.
Delivering a large-scale battery storage system in Europe
"That is also our goal in the Netherlands," says Jacob Jan Stuyt, Commercial Director and head of the Dutch Developer and Capacity provider SemperPower. His battery storage facility is one of the largest in Europe and is supported by 168 Rolls-Royce mtu EnergyPack QGs.
Each mtu EnergyPack has a capacity of eight megawatts. Two inverters in the middle of the system ensure that the energy, which is stored in the battery in the form of direct current, is converted into alternating current and fed via the transformers to a Medium Voltage station supplied by Rolls-Royce and onto the public grid.
Ensuring maximum performance through our intelligent control system
Alongside providing mtu EnergyPacks, seven inverters and our intelligent mtu EnergetIQ control platform, we were responsible for the construction of the entire battery storage facility. “The team from Rolls-Royce really did a great job here and installed the entire system within nine months," explains Jacob.
“This system also works so well thanks to our mtu EnergetIQ control platform,” says Tom Kuiper, a specialist in battery storage at Rolls-Royce's Power Systems division. “mtu EnergetIQ is the brain of the entire system and controls the interaction of all the system's components," he explains. “Our expertise lies not in supplying the individual components, but in linking them together in such a way that our customers can achieve maximum performance with them.”
A partner for long-term reliability
Over the next five years, SemperPower will install two gigawatts of battery storage capacity. “We need the best partners for this - like Rolls-Royce," says Jacob. The company will also benefit from a long-term mtu ValueCare maintenance contract, ensuring that the batteries remain reliably ready for use. In addition to predictive maintenance, this primarily includes capacity guarantees for the first ten years. “With this guarantee from Rolls-Royce, we can in turn guarantee capacity to our customers - that is the basis of our business
ErnieBilco
3 months ago
Rolls-Royce SMR Limited (Rolls-Royce SMR) and CEZ Group (CEZ) have today announced that they will join forces to bring their global capabilities and know-how to the deployment of Rolls-Royce SMR’s small modular reactor (SMR) technology. This is enabled by an equity investment by CEZ into Rolls-Royce SMR and a strategic partnership to deploy up to 3GW of electricity in the Czech Republic using Rolls-Royce SMR power plants.
The agreement strengthens Rolls-Royce SMR’s ability to deploy SMR technology in Europe and globally, and puts CEZ, Rolls-Royce SMR, and its existing shareholders, BNF Resources, Constellation, QIA and Rolls-Royce at the forefront of SMR deployment. These efforts further support the UK and Europe to reach their ambitious net zero goals and contribute solutions to address the challenges of climate change.
Tufan Erginbilgiç, CEO of Rolls-Royce plc, said:
We are pleased to receive this significant opportunity to deploy our SMR technology in the Czech Republic and welcome CEZ as a strategic investor and partner in Rolls-Royce SMR. We have a shared vision and CEZ further strengthens our ability to build stable, secure, low carbon power - delivering on our promise as a leading SMR business. Today’s announcement ensures that the Rolls-Royce SMR business is set up for success in the UK, the Czech Republic and around the world.”
ErnieBilco
4 months ago
Press release from 2 days ago:
Rolls-Royce is one step closer to powering the next generation aircraft for the U.S. Army. On August 2, the Future Long Range Assault Aircraft (FLRAA) became an official program of record when the U.S. Army announced its Milestone B decision, moving the program, led by prime contractor Bell Textron Inc., a Textron Inc. company, into the engineering and manufacturing development phase.
As part of Team FLRAA, Rolls-Royce will deliver a complete propulsion solution for the tiltrotor aircraft, featuring two AE 1107F engines and a fully integrated system design. The AE 1107F engine is the continued evolution of our proven AE engine family, providing the performance and reliability needed to power the transformational capabilities of FLRAA.
Cathy Welch, Program Director - FLRAA for Rolls-Royce Defense, said:
The Milestone B decision is a testament to the strength of Team FLRAA and the confidence the U.S. Army continues to show in this key modernization program. Rolls-Royce is thrilled to reach this historic milestone with our teammates at Bell and the U.S. Army, and as FLRAA moves into the engineering and manufacturing development phase, we are keeping our sights set on delivering revolutionary capabilities to the U.S. Army."
Since 2015, Rolls-Royce has invested more than $1 billion in modernizing its Indianapolis facilities to deliver innovation and advanced manufacturing to the U.S. Army and other customers with American labor. The AE1107F engine will be manufactured, assembled and tested in Indianapolis, Rolls-Royce’s largest production facility in the U.S.
The AE engine family has achieved 88 million flight hours of service worldwide. The AE 1107C engine has completed 1.4 million flight hours with more than two decades of service on the V-22 Osprey. The AE 1107F will build off that proven pedigree to power FLRAA and deliver twice the speed and twice the range of any traditional rotorcraft platform in the current U.S. Army fleet.
ErnieBilco
5 months ago
Today's news:
Rolls-Royce (LSE: RR., ADR: RYCEY) has reached an agreement to sell its Naval Propulsors & Handling business to Fairbanks Morse Defense. The sale comprises the naval propulsors units in Pascagoula, Mississippi and Walpole, Massachusetts, in the US, as well as the specialized naval handling systems unit in Peterborough, Ontario, Canada.
The Naval Propulsors & Handling business manufactures and supports a range of specialist propellers and waterjets for naval applications, as well as specialized handling systems that enable the deployment and recovery of manned and unmanned craft, and other cargo, from naval vessels.
Rolls-Royce will retain its Naval Gas Turbines and Generator Sets operations, which provide power dense solutions for naval propulsion and onboard power needs.
Adam Riddle, President – Defense and Chairman & CEO, Rolls-Royce North America, said:
Rolls-Royce Naval Propulsors & Handling is an industry leader and trusted supplier to navies around the world. We are pleased to collaborate with Fairbanks Morse Defense, who recognizes the value of this business and the outstanding opportunities for its strong future. We believe this transaction represents the best outcome for the business, its people and the military customers they serve."
Last year, Rolls-Royce presented its strategy to become a high performing, competitive, resilient and growing business to investors. In Defense, the focus is on strategic growth in the areas of combat, transport and submarines.
Until the transfer of the Naval Propulsors & Handling business is complete, Rolls-Royce Defense will continue its activities unchanged to ensure that customer relationships, delivery and service obligations remain unaffected.
This sale is subject to customary closing conditions, including regulatory review and approval. The financial details of the sale are not being disclosed.
ErnieBilco
7 months ago
Found this just a short while ago, thought it might interest you.
And I hope it goes without saying that we have no idea whether investors will get lusty about either of these in the coming months — always possible, almost never predictable. If you want something much more conventional and predictable, and currently profitable, you could probably do worse than BWX Technologies (BWXT) or Rolls-Royce (RR.L, RYCEY, RYCEF) among the more diversified SMR hopefuls… or the big utilities who own a lot of large conventional nuclear reactors, like Constellation Energy (CEG) and Vistra (VST), who are also seeing their day in the sun right now. None have anywhere near the growth potential of Oklo or NuScale if their designs really take off over the next decade and go into mass production… but none are as likely as those startups to lose 90% of their value in the next few years, either.
This was in a Stock Gumshoe analysis of SMRs (Small Modular Reactors) which RR is heavily into development.
ErnieBilco
11 months ago
News out today:
Rolls-Royce today welcomed the announcement that the Australian Government would be investing in its ongoing AUKUS preparations. This supplements the expansion funding already committed by the UK Ministry of Defence (MOD).
To meet the growth in demand from the Royal Navy, which includes AUKUS delivery commitments, work is already underway to double the size of the Rolls-Royce Submarines site in Raynesway, Derby.
Now jointly funded by UK MOD and the Australian Department of Defence, the expansion work announced last summer will create over 1,000 new jobs in Derby across a range of disciplines, including manufacturing and engineering. It will also see new manufacturing and office facilities being built on recently acquired land surrounding the existing Raynesway site.
In March 2023 it was confirmed that Rolls-Royce Submarines would provide all the nuclear reactor plants that will power new attack submarines as part of the tri-lateral agreement between Australia, the UK and US.
Rolls-Royce Submarines President Steve Carlier said:
Last year we were proud to welcome the Hon Richard Marles MP, Australia’s Deputy Prime Minister and Minister for Defence, and UK Defence Secretary Grant Shapps, to our Raynesway site to showcase some of the world-class manufacturing and engineering capabilities we have developed over the last 60 years.
This commitment of funding to our existing expansion work shows the trust Australia places on our nuclear expertise and our ability to deliver. We look forward to working with the Australian Submarine Agency to support them in building their own fleet of nuclear-powered submarines.”
Grant Shapps MP, UK Secretary of State for Defence, said:
In a more dangerous world, today’s announcement symbolises the huge confidence our close partner Australia has in our world-leading defence industry, including companies such as BAE Systems and Rolls-Royce.
Through these collaborations, British industry will grow, and thousands of jobs created across the country, delivering security and prosperity to our two nations.”
To support preparation for AUKUS and to meet the additional commitments to the MOD, Rolls-Royce recently announced the opening of two satellite offices in Glasgow and Cardiff. The locations were selected to help access the skilled talent pools in both regions, with more than 100 jobs being created in each city.
To further ensure a steady pipeline of future talent into the industry, Rolls-Royce opened a new Nuclear Skills Academy in Derby in 2022. It will provide 200 apprenticeships each year for at least the next decade.
Rolls-Royce Submarines currently employs more than 4,000 people and designs, manufactures and provides in-service support to the pressurised water reactors that power every boat in the Royal Navy’s submarine fleet.
Rolls-Royce is currently supporting the existing Astute and Dreadnought boat build programmes through the delivery of reactor plant and associated components. Additionally, it provides frontline support across the world for reactor plant equipment from its Operations Centre in Derby and supports the submarines when in the Barrow-in-Furness shipyard and the naval bases at Devonport and Faslane.
ErnieBilco
11 months ago
Feb PR:
Rolls-Royce (LSE: RR., ADR: RYCEY) today announces a commitment by Vietjet Air for 20 Trent 7000 powered A330neo, which will complement the airline’s existing widebody fleet of seven Trent 700 powered A330ceo aircraft.
With a laser focus on sustainability, Vietjet Air has committed to the A330neo/Trent 7000 combination as it delivers a 14% better fuel burn per seat, whilst significantly lowering emissions. The reduction in emissions will allow the airline to avoid more than one hundred thousand tons of CO2 over the lifetime of each aircraft.
The Trent 7000 draws on the technology and experience of the most advanced family of engines in the world. As the latest member of the Trent family, the Trent 7000 is based on Trent XWB technology and has delivered exceptional reliability since its entry into service.
Ewen McDonald, Chief Customer Officer, Rolls-Royce – Civil Aerospace, said:
Today’s commitment demonstrates Vietjet Air’s confidence in the power of the Trent 7000 to deliver significant sustainability gains alongside a reliable and consistent customer experience. We are proud to continue supporting Vietjet Air as they expand their operation responsibly and sustainably over the coming years.”
Vietjet Air, Chief Executive Officer, Dinh Viet Phuong, said:
The combination of modern Trent 7000 engines on the newest generation of Airbus A330neo will help Vietjet Air reach new technological heights, improve the quality of our flights, and increase the reliability and efficiency of our operations. Specifically, the addition of newest generation, high-efficiency Rolls-Royce engines will contribute significantly to Vietjet Air’s ESG plan to achieve net zero emissions by 2050.”