Constellium and TARMAC Aerosave achieve breakthrough in recycling end-of-life aircraft aluminum; companies successfully remelt recovered aluminum into aerospace-grade material using 95% less energy than primary production

On Thursday, June 12, aluminum producer Constellium SE and TARMAC Aerosave, a pioneer in aircraft & engine storage, maintenance, and eco responsible dismantling, announced jointly the successful recycling and remelting of aluminum from end-of-life aircraft into new, high-performance material suitable for future aerospace applications.

According to the press release, this milestone in sustainable aerospace innovation highlights the potential of aluminum to support circular economy goals in aerospace, without compromising material performance.

Following months of collaborative research and development, Constellium has successfully remelted aluminum recovered by TARMAC Aerosave from retired commercial aircraft, producing material that meets the stringent performance requirements for new aircraft manufacturing. The next step will be to scale up this process for industrial application and to extend it to any aluminum alloy used in metallic aircraft, further demonstrating the full recyclability of end-of-life metallic airframes.

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

Aluminum recycling uses only 5% of the energy required for primary production and emits 95% fewer CO₂ emissions. Recycling also protects resources and reduces waste, making it a powerful lever for improving the sustainability of the aerospace industry.

“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,” said Alexandre Brun, President and CEO of TARMAC Aerosave.