How 3D printing revitalized the IAF fleet in preparation for the strikes on Iran
The use of AM at Air Maintenance Unit 22 in Tel Nof helped to obtain key spare parts in the build up to Operation Rising Lion
Operation Rising Lion came at a particularly challenging moment for the IAF. With only unmanned aerial vehicles (UAVs) and about one and a half squadrons of F-35s—still awaiting full delivery—the rest of the fleet, including F-15s and F-16s, remains outdated by Western standards. These aging machines required a substantial amount of spare parts to perform adequately during one of the most daring missions the IAF has ever undertaken. According to the Israeli news outlet Ynet, many of these parts were no longer accessible, as several governments around the world refused to supply Israel due to their opposition to the war in Gaza. This is where 3D printing became crucial.
In total, the core of the fleet comprises older models of the F-16 and F-15, Boeing 707-based refueling tankers, vintage C-130 Hercules transport planes, and Sikorsky CH-53 Sea Stallion helicopters, known locally as Yasur helicopters, some of which have been in service since the Entebbe operation. Toward the end of 2024, the Israeli Defense Ministry, the Air Force, and the IDF’s Planning Directorate quietly initiated a complex and urgent operation to meet the expectations of Air Force Chief Tomer Bar.
Inspections confirmed what was already suspected: although the aircraft were fit for short-range strikes against targets like Hamas or Hezbollah, they were not prepared for long-range missions to Iran, about 930 miles each way, which require mid-air refueling and rapid rearming. These older aircraft needed specialized attention and numerous spare parts, many of which are no longer produced by the original manufacturers, such as Lockheed Martin, Sikorsky, and Boeing.
“We quietly enlisted the manufacturers, without disclosing the full reason, but they didn’t have all the solutions,” an IAF officer revealed. “So we turned to friendly nations to ask for rare spare parts. These were added to components 3D printed here, mainly at the central maintenance unit at Tel Nof. We even approached defense ministers from countries that publicly condemn us over Gaza, convincing them to give up rare stockpiles. They didn’t know why.”
As reported by the Indian defense publication Raksha Anirveda, which was granted access to the base in 2022, 3D printing is becoming increasingly essential to the Israeli Air Maintenance Unit, both for parts and for servicing heavy aircraft. Air Maintenance Unit 22, located at Tel Nof, is the premier technical division of the IAF. It is responsible for the heavy maintenance of all aircraft in the fleet and, when necessary, manufactures parts and assemblies in-house, including a growing number of 3D printed components.
Due to the unavailability of many spare parts on the commercial market, the IAF has turned to 3D printing as a solution. In several instances, the newly printed components are not only replacing outdated ones but are also lighter and more durable than parts manufactured using now-obsolete processes. The unit’s engineers are producing 3D printed components made from materials such as aluminum, titanium, and advanced composites.
An IAF representative told Raksha Anirveda that the unit is also partnering with academic institutions in Israel to enhance its 3D printing capabilities further. The team faces ongoing technical challenges, particularly when upgrading aircraft that should have been retired years ago. One notable example is the CH-53 heavy-lift helicopter. Although the IAF has recently selected the CH-53K as its new heavy-lift platform, the older CH-53s will remain operational for several more years.
While the unit follows manufacturer guidelines, the extensive hands-on experience accumulated by its engineers and technicians plays a crucial role in their work. When the IAF opted for the F-35, it decided against sending the stealth jets to international maintenance centers. As a result, a specialized hangar is currently under construction at Tel Nof to handle all of the F-35’s heavy maintenance needs.
The unit also serves as the primary maintenance center for all medium- and large-sized UAVs operated by the IAF. Given that approximately 80% of the IAF’s flight hours are now performed by UAVs, these sophisticated systems undergo regular maintenance and upgrades at Tel Nof. Since UAVs are primarily made of composite materials, the unit has become highly proficient in fabricating and repairing composite parts.
The unit takes pride in its tradition of restoring aircraft that might otherwise be scrapped in other air forces, ensuring that even damaged machines are brought back into active service.
