3D Printing for a Circular Economy: Upcycling Aircraft Scrap with AFSD

Since 2021, aircraft retirements have declined due to COVID-related global supply chain challenges, requiring aging in-service fleets to remain operational rather than be replaced by new production aircraft. However, as production capacity rebounds, aircraft retirements are expected to recover and grow. The bulk of this end-of-life material is aluminum, which is essential in aircraft structures, accounting for 80% of the total weight in current-generation aircraft. With a growing volume of aluminum scrap—both from machining chips and retired aircraft—there is a need for innovative solutions to recycle this material. This effort pursues a novel approach to upcycle this scrap into useful products, reducing environmental impact and supporting a sustainable circular economy.
This presentation explores a proof-of-concept feasibility study on upcycling machining chips and end-of-life aircraft scrap metal using Additive Friction Stir Deposition (AFSD) technology. It compares the material properties achieved from virgin materials, machining chips, and aircraft scrap, highlighting the implications and potential applications of AFSD for sustainable metal upcycling.