Aircraft and engine storage, maintenance and dismantling firm, TARMAC Aerosave, and aluminum solutions and recycling provider, Constellium, have achieved a major breakthrough in sustainable aerospace by successfully recycling aluminium from end-of-life aircraft into high-performance material suitable for use in new aircraft manufacturing.

The milestone demonstrates the viability of a full circular economy model for metallic aircraft components, highlighting the potential to significantly reduce waste and carbon emissions without sacrificing material quality.

The achievement follows months of joint research and development, supported by Airbus and recycling specialist ValoER.

Using aluminium recovered from retired aircraft by TARMAC Aerosave, Constellium remelted the material into aerospace-grade aluminium that meets the stringent performance standards required for new aircraft production.

With aluminium recycling requiring just 5% of the energy of primary production and producing 95% fewer CO₂ emissions, the collaboration underscores the environmental benefits of circularity in aviation materials.

The next step will be to scale the process to industrial levels and expand it to include a wider range of aluminum alloys used in aircraft manufacturing.

As the aerospace industry accelerates efforts to lower its environmental impact, the success of this initiative offers a promising model for sustainable innovation.

TARMAC Aerosave‘s president and CEO, Alexandre Brun, said: “The circularity of aeronautical materials is at the heart of TARMAC Aerosave’s DNA. It’s what built its worldwide reputation as a leader in aircraft recycling, before becoming a one-stop shop.

“Aluminum is one of the materials that we have always sought to sort and recover in the best possible way in order to increase our recycling rate, which is now more than 92%. We’re proud to have joined forces with partners who share our commitment to advancing circular solutions for aviation.”

Philippe Hoffmann, president of Constellium’s aerospace and transportation business unit, said: “At Constellium, recycling is at the core of what we do. We have extensive experience in giving aluminum an endless life across various industries.

“What makes this initiative truly exciting is that it demonstrates – through a real-world example – that even complex aerospace aluminum alloys from end-of-life aircraft can be fully recycled into material suitable for new aerospace applications. It’s a proof point for the circular economy in aviation.”

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