A revolutionary hybrid manufacturing process developed by Shropshire-based SDE Technology could transform aerospace production by reducing superplastic forming cycle times by 50% and cutting costs by 25%. Supported by the Advanced Forming Research Centre (AFRC) and industry giants Boeing and Timet UK, the project aims to strengthen the UK’s position in high-value aerospace manufacturing by enabling faster, more efficient production of complex titanium components.
Collaborative Innovation for Aerospace Efficiency
The new method combines innovative tooling with optimized thermal processing, reducing forming temperatures to 800°C—significantly lower than traditional approaches. This not only slashes energy consumption but also minimizes the formation of alpha case, a brittle oxide layer that typically requires costly chemical removal. “Our research demonstrates this hybrid process can match traditional quality standards while dramatically improving efficiency,” said Evgenia Yakushina, AFRC’s forming team lead, whose group brings 200+ years of materials expertise to the project.
Scaling Up for Industrial Adoption
Funded by the Aerospace Technology Institute (ATI), the 18-month NATEP-backed initiative will validate the technique for industrial-scale aerospace applications. SDE Technology CEO Richard Homden highlighted the strategic shift: “With AFRC’s support, we’re transitioning into hot forming—a potential cornerstone of our future business—and positioning the UK as a key supplier for Boeing’s supply chain.”
Sustainability and Supply Chain Benefits
Additional funding will assess the method’s carbon footprint reduction, leveraging shorter heating cycles and lower temperatures. David Milliken, Boeing’s forming technical lead, emphasized the project’s global potential: “Advancing UK manufacturing processes aligns with our commitment to worldwide innovation partnerships.”
Aerospace Industry Embraces Disruptive Potential
With Timet UK also endorsing the technology’s problem-solving capabilities, the collaboration signals a broader shift toward leaner, greener aerospace production. If successfully scaled, the technique could redefine titanium component manufacturing for next-generation aircraft.
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