The NAVAIR Additive Manufacturing crew helps Navy and Marine Corps maintainers with AM coaching, engineering assist, and technical knowledge to extend readiness in forward-deployed places the place conventional logistics are contested. Lately, Marine Plane Logistics Squadron 36 (MALS-36) and 18th Upkeep Group (18 MXG) maintainers used AM to return a US Air Power F-15 Eagle to the struggle in hours, a number of months forward of its projected return to service date.
Additive manufacturing is strengthening its function as a power multiplier within the Air Power, in keeping with Depot Liaison Engineer US Air Power Captain Diego Carrillo. “In functions the place 3D-manufactured elements are a viable choice and are non-procurable or have an extended lead time, utilizing this functionality can provide value and time financial savings. This functionality is vital when objects aren’t obtainable from the availability chain or can’t be bought from trade when wanted.”
This was the case with an F-15’s right-hand cockpit cooling duct. When Air Power maintainers at Kadena Air Base, Okinawa, Japan, found the crack throughout inspection after a flight, they estimated that the plane can be grounded for 3 to 4 months. At first, they sought to restore it utilizing conventional restore processes with the intent of utilizing as a lot of the unique materials as doable. After consulting with a depot liaison engineer, nonetheless, they turned to additive manufacturing to print and exchange the merchandise.
Initially, 18 MXG maintainers printed out two prototypes however skilled technical difficulties earlier than they might print an element that met specs. Figuring out MALS-36 had the identical machine, they reached out to them for help. Two prototypes have been printed, delivered, and match checked in lower than 12 hours.
The collaboration yielded one other surprising profit: after analyzing the Air Power’s technical knowledge bundle, the Marines got here up with an improved design that lowered the half’s print time by two hours.
“We have been skeptical of the primary design offered by [the MALS] as a result of important shorter print time in comparison with our first prints. Our techs realized that the duct’s orientation impacts the need for the assist constructions, which allowed the Marines to scale back the duct’s print time with out compromising its structural integrity,” he mentioned.
“Right here was a state of affairs the place a multi-million greenback plane was going to be sidelined for months as a result of lack of an element within the provide system,” mentioned NAVAIR Additive Manufacturing Program Supervisor Theodore Gronda. “The Air Power’s proactive, forward-leaning maintainers sought and obtained approval to restore the half utilizing their on-site AM functionality. 18 MXG was backstopped by MALS-36’s AM functionality, they usually even received a greater and faster AM design out of the collaboration. This was really a glowing instance of a ‘One Group, One Combat’ effort.”
Carrillo sees the outcomes of this effort going past a single plane and the Air Power. “The duct’s new printing necessities at the moment are a part of the Air Power’s AM technical publications and might be used for related repairs throughout the F-15 neighborhood,” he mentioned. “Cooperative and joint workouts with sister providers and different stakeholders will help cross-pollinate concepts and methodologies, strengthen partnerships, and enhance power effectiveness.”
