[3D Printing] BAE Systems Uses 3D Printing to Build New Tempest Fighter Demonstrator
BAE Systems is producing a supersonic demonstrator aircraft to support the Global Combat Air Programme (GCAP).
The crewed aircraft prototype will be used to test a range of new technologies, including stealth-compatible features.
These tests will be the UK's first combat air demonstrator in 40 years, supporting the development of the next-generation "Tempest" fighter.
GCAP, launched in 2022, combines Japan's F-X program with the UK and Italy's Team Tempest program. The company is working to produce a sixth-generation supersonic fighter by 2035.
The British defense company is leveraging additive manufacturing to produce major structural components for the demonstrator, most of which are being manufactured in the UK.
Paul Wilde, Head of Tempest at BAE Systems, stated: "Some parts on the aircraft simply could not be manufactured any other way now than using additive processes."
It has been known that 3D printing plays a critical role in the development and manufacturing of the Tempest fighter. BAE previously claimed that 30% of Tempest's parts would be 3D printed.
The company also unveiled the latest design for the GCAP fighter, showcasing a life-size demonstrator at the Farnborough International Airshow. The model incorporated new design features, including a larger wingspan than previous concepts. This is reportedly to improve the aircraft's aerodynamic performance.
BAE 3D Prints Sixth-Generation Fighter
BAE officials reported that the aircraft passed its Critical Design Review (CDR) in May. Half the weight of the aircraft prototype has now been manufactured or assembled, with the front-centre, rear, and wing sections currently under construction.
Structural components are being produced using additive manufacturing processes, including industrial 3D printing and hot isostatic pressing (HIP).
HIP presses titanium powder together at high temperatures and pressures to produce metal parts. This minimizes waste and significantly reduces lead times associated with forgings. According to BAE, project engineers also utilized Design for Additive Manufacturing (DfAM) when producing structural parts.
The time savings from additive manufacturing could play a crucial role in shortening the Tempest's development time. The aircraft is expected to be delivered just 12 years after the trilateral agreement is signed. This is roughly half the time it took to produce the previous-generation Eurofighter Typhoon.
According to the Financial Times, BAE is 3D printing molds that will be used to manufacture Tempest's carbon fiber parts. These "tooling molds," traditionally made from steel, typically take 26 weeks to produce using conventional manufacturing methods. Using additive manufacturing, BAE can produce a complete tool in just three weeks.
By creating "Tempest", GCAP aims to produce one of the world's most advanced, interoperable, adaptable, and connected fighter jets. It will integrate smart weapon systems, software-driven interactive cockpits, and integrated sensors. The next-generation radar will reportedly offer 10,000 times more data than current systems.
According to BAE, "Tempest" will also be the first British-built tactical fighter since the 1958 "Blackburn Buccaneer" to feature an "integrated payload bay." The aircraft's avionics will feature a modular, adaptable, and software-driven flight platform design architecture, increasing its adaptability.
BAE's demonstrator will provide evidence for key technologies, methods, and tools adopted in future combat air systems.
In Warton, Lancashire, test pilots from BAE Systems, Rolls-Royce, and the Royal Air Force (RAF) have already spent over 215 hours in the demonstrator's flight simulator. While the Tempest demonstrator program is a sovereign UK project, the lessons learned will feed into the trilateral GCAP program.
Japan has already test-flown its future fighter demonstrator, the Mitsubishi X-2, which first flew in 2016.
3D Printing-Enabled Fighter Jets
By adopting additive manufacturing in fighter jet production, Western countries are seeking to gain an advantage in an increasingly challenging geopolitical environment. However, Russia and China are also using 3D printing to enhance their military aircraft production capabilities.
The Russian military previously used 3D printing to upgrade MiG-31 jets. These upgrades, carried out by UEC-Perm Motors and UEC-Star, a subsidiary of the state-owned Rostec group, significantly improved the interceptor's engine performance.
Reportedly, engineers from UEC-Perm Motors and UEC-Star 3D printed parts for the MiG's D-30F6 engine, enabling it to reach "a new level of quality." Additional R&D reportedly led to the production of "indigenous engines" capable of delivering "better performance." This followed Rostec obtaining a permit from Russia's Ministry of Industry and Trade for the mass 3D printing of aerospace parts. This came after the successful testing of state-backed additive manufacturing aircraft engines.
China's Shenyang Aircraft Corporation (SAC) has reportedly used 3D printing extensively in fighter jet production. Additive manufacturing technology is understood to make aircraft component assemblies lighter and more durable.
In 2022, Dr. Li Xiaodan of Shenyang Aircraft Corporation Process Institute told CCTV, "3D printed parts have been widely used in the newly developed aircraft that made its maiden flight not long ago." He added, "We are at the world's leading level in large-scale application of 3D printing technology in aircraft at an engineering level."
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