Constellium and TARMAC Aerosave Achieve Breakthrough in Full-Circular Aluminum Recycling for End-of-Life Aircraft

Rhea-AI Summary

Constellium (NYSE: CSTM) and TARMAC Aerosave have achieved a significant breakthrough in aerospace sustainability by successfully recycling and remelting aluminum from end-of-life aircraft into new, high-performance material suitable for future aerospace applications. The collaborative project, supported by Airbus and ValoER, demonstrates the potential for a circular economy in aviation while maintaining strict performance standards. TARMAC Aerosave currently achieves a 92% recycling rate in aircraft recycling. The process is notably environmentally friendly, using only 5% of the energy required for primary aluminum production and generating 95% fewer CO2 emissions. This breakthrough represents a significant step toward reducing the aerospace industry's carbon footprint and establishing a sustainable, circular model for aircraft materials.

Positive

• Successfully demonstrated full recyclability of complex aerospace aluminum alloys while maintaining performance standards
• Process uses only 5% of energy compared to primary production with 95% lower CO2 emissions
• TARMAC Aerosave achieves high 92% recycling rate in aircraft recycling
• Partnership with major industry players including Airbus supports industrial scaling potential

Negative

• Process still needs to be scaled up for industrial application
• Currently limited to specific aluminum alloys, needs extension to cover all aircraft aluminum types

Insights

Aerospace Materials Engineer

Constellium's aircraft aluminum recycling breakthrough represents significant advancement in aerospace sustainability with substantial cost and environmental benefits.

This recycling breakthrough by Constellium and TARMAC Aerosave represents a significant technical achievement in aerospace materials science. The ability to recycle complex aerospace aluminum alloys from end-of-life aircraft into new materials that meet stringent aerospace specifications solves a long-standing industry challenge. Most aerospace alloys contain specialized elements and precise compositions that historically made closed-loop recycling difficult without performance degradation.

The energy implications are substantial - aluminum recycling requires just 5% of the energy needed for primary production and generates 95% fewer CO₂ emissions. For context, primary aluminum production is extremely energy-intensive, consuming approximately 14,000 kWh per ton. A 95% reduction translates to potential savings of 13,300 kWh per ton of recycled aerospace aluminum.

TARMAC's current 92% recycling rate for aircraft dismantling is already industry-leading, but this closed-loop capability moves beyond simple recycling into true circularity. The collaboration with Airbus indicates potential industry-wide adoption, which could dramatically reduce the environmental footprint of aircraft manufacturing.

With aluminum comprising approximately 80% of an aircraft's unladen weight, this technology has the potential to revolutionize end-of-life aircraft value and redefine materials sustainability in aerospace. The process, once scaled industrially, will likely become a competitive advantage as aerospace manufacturers face increasing pressure to reduce emissions across their supply chains.

Sustainable Investment Analyst

Constellium's breakthrough in full-circular aluminum recycling represents a potentially valuable competitive advantage in the evolving aerospace manufacturing landscape. This development aligns perfectly with the industry's intensifying focus on reducing environmental impact and meeting increasingly stringent ESG requirements.

The economics are compelling. By recycling aluminum from end-of-life aircraft, Constellium can achieve substantial cost advantages through 95% reductions in energy consumption and associated emissions. This creates a dual benefit: reduced production costs and enhanced environmental credentials. As carbon pricing mechanisms expand globally, these emissions reductions could translate to significant avoided costs.

The partnership with TARMAC Aerosave and implicit endorsement from Airbus suggests this technology has credibility with major industry players. Importantly, the press release specifies that the recycled material meets "stringent performance requirements for new aircraft manufacturing" - indicating no compromise on quality, which has historically been a barrier to closed-loop recycling in aerospace applications.

While currently at pilot scale, the pathway to industrialization appears well-defined, with plans to extend the process to "any aluminum alloy used in metallic aircraft." This positions Constellium advantageously in an industry increasingly focused on lifecycle impacts. As OEMs and airlines face mounting pressure to reduce Scope 3 emissions, suppliers offering circular solutions will likely gain preference in procurement decisions.

The timing aligns with accelerating industry sustainability commitments and regulatory pressures, potentially allowing Constellium to capture premium pricing for lower-carbon materials while strengthening relationships with key aerospace customers.

PARIS, June 12, 2025 (GLOBE NEWSWIRE) -- Constellium SE (NYSE: CSTM), a global leader in aluminum solutions and recycling, and TARMAC Aerosave, a pioneer in aircraft & engine storage, maintenance, and eco-responsible dismantling, are proud to jointly announce a major milestone in sustainable aerospace innovation: the successful recycling and remelting of aluminum from end-of-life aircraft into new, high-performance material suitable for future aerospace applications.

This milestone highlights the potential of aluminum to support circular economy goals in aerospace, without compromising material performance. Following months of collaborative research and development, supported in particular by Airbus and ValoER, 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.”

“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. Aluminium 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.

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. As the sector intensifies efforts to reduce its carbon footprint, this full-circular model provides a compelling path forward for future innovation and sustainability.

About Constellium

Constellium (NYSE: CSTM) is a global sector leader that develops innovative, value-added aluminum products for a broad scope of markets and applications, including aerospace, packaging and automotive. Constellium generated $7.3 billion of revenue in 2024.
www.constellium.com

About TARMAC Aerosave

TARMAC Aerosave is a leading specialist in aircraft and engine maintenance and transition, founded by Airbus, Safran Aircraft Engines and Suez. Operating Europe’s largest aircraft storage and maintenance facilities across three sites in France and Spain, the company also pioneers eco-responsible dismantling processes that maximize material recovery and minimize environmental impact.
www.tarmacaerosave.aero

Media Contacts
TARMAC Aerosave	Constellium
Pascale Nizet	Angelique du Rostu
Press Officer	External Communications Director
Phone: +33 1 48 16 10 95	Phone: + 33 (0)1 73 01 46 11
pascale.nizet@ozelys.aero	angelique.durostu@constellium.com

FAQ

What breakthrough did Constellium (CSTM) achieve in aircraft recycling?

Constellium successfully recycled and remelted aluminum from end-of-life aircraft into new, high-performance material that meets requirements for new aircraft manufacturing

How much energy does Constellium's aircraft aluminum recycling process save?

The recycling process uses only 5% of the energy required for primary aluminum production and emits 95% fewer CO2 emissions

What is TARMAC Aerosave's current recycling rate for aircraft materials?

TARMAC Aerosave achieves a recycling rate of more than 92% for aircraft materials

What are the next steps for Constellium's aircraft aluminum recycling program?

The next steps are scaling up the process for industrial application and extending it to all aluminum alloys used in metallic aircraft

Who are the partners involved in Constellium's aircraft recycling breakthrough?

The project is a collaboration between Constellium, TARMAC Aerosave, Airbus, and ValoER