US Navy testing 3D printed fighter jet parts for quick repairs — composite parts printed at forward-deployed 3D printers to be flight tested on operational F/A-18 Super Hornets
F/A-18 Super Hornets and other jets that require advanced composite parts can sometimes remain grounded for a protracted period due to the lack of available parts. The U.S. Navy now wants to solve this issue by giving maintenance sites around the world the ability to 3D print these parts on site, instead of waiting for deliveries coming from thousands of miles away through an extended logistics chain. According to the Department of Defense’s information distribution service, this 3D-printing repair method will allow the U.S. Navy to repair and replace advanced composite parts at forward operating bases, cutting repair time by around 50%.
“Our goal is to put capability directly into the hands of the Fleet,” Naval Air Warfare Center Aircraft Division (NAWCAD) Commander Rear Adm. Todd Evans said. “By simplifying a complex repair so it can be done forward, our engineers would get aircraft back in the fight faster — it’s a smart solution that makes our squadrons more self-sufficient and directly improves operational readiness.”
Composite parts are more difficult to repair than traditional aluminum parts and require specialized experience. This new technique allows troops to 3D-print composite patches and apply them directly on the aircraft, instead of having to order and wait for complete replacements of damaged panels. Laboratory and ground tests have already proved the viability of these 3D printed repairs, so the next step is to see how these repairs will perform in the field under the stresses of real-world operations.
Other military branches and divisions are also experimenting with 3D printing to streamline operations and logistics. One Hawaiian startup submitted a 3D-printed rigid-hull inflatable boat (RHIB) for the Pentagon which used radar-absorbent material (RAM) to reduce its radar cross-section (RCS) and make them harder to detect. The U.S. Army also introduced a three-week course called the Unmanned Advanced Lethality Course (UALC), which trained soldiers how to operate and 3D print drones in the field, as well as 3D printer maintenance and other necessary skills related to 3D printing. The U.S. Marine Corps also developed its own modular 3D-printed drone that had no China-sourced parts capable of achieving various missions, from reconnaissance to one-way attack duties.
3D printing is quickly becoming a crucial manufacturing technique for these military branches, especially as the U.S. faces a threat across the Pacific. If ever a conflict arises in this area, it would face a near-peer adversary at the tail end of a logistics chain thousands of miles long. By giving forward bases the ability to 3D print their own parts and supplies, it will reduce their dependence on a vulnerable supply chain while also allowing them to speed up maintenance and repairs.
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