---
title: "McConnell AFB Innovation Lab 3D prints a fix for KC-46 engine servicing"
url: https://www.voxelmatters.com/mcconnell-afb-innovation-lab-3d-prints-a-fix-for-kc-46-engine-servicing/
date: 2026-07-31
modified: 2026-07-31
lang: en
author: "Joseph Caron-Dawe"
description: "A maintenance problem at McConnell Air Force Base's Innovation Lab led to the creation of a 3D printed funnel, which is now being used to service the KC-46A Pegasus's engine..."
categories:
  - "Aerospace AM"
  - "Aviation"
  - "Defense"
tags:
  - "future"
image: https://www.voxelmatters.com/wp-content/uploads/2026/07/USAF-3D-printed-engine-funnel-01.jpg
word_count: 356
---

# McConnell AFB Innovation Lab 3D prints a fix for KC-46 engine servicing

A maintenance problem at McConnell [Air Force Base](https://www.voxelmatters.com/us-air-force-base-using-on-site-am-lab-to-overcome-supply-chain-issues/)'s Innovation Lab led to the creation of a 3D printed funnel, which is now being used to service the KC-46A Pegasus's engine starter.

The part reduces oil spillage during maintenance and was specially created by Tech. Sgt. Brandon Branstetter, a crew chief with the 22nd Aircraft Maintenance Squadron. He designed and printed the tool after concluding that no commercial product matched the funnel's required shape and maneuverability.

![McConnell AFB Innovation Lab 3D prints a fix for KC-46 engine servicing](https://www.voxelmatters.com/wp-content/uploads/2026/07/USAF-3D-printed-engine-funnel-02-340x224.jpg)

“They were essentially using a turkey baster to service the KC-46 engine starter,” Branstetter said. “It was dripping oil onto the ground, and I knew there had to be a better way to solve the problem.”

## From CAD model to printed tool

Branstetter measured the dimensions needed, built a model in CAD software, and produced the first prototype on a Bambu Lab H2D printer. He tested several materials before selecting TPU for the final part.

“We made it out of TPU because it is oil and fuel resistant, so it won't break down after continuous use,” he explained.

“It was a real specific design because of how the funnel needed to go across, but still be angled to where it could reach. It just had real specific and challenging dimensions.”

## A low-cost, in-house alternative

Test versions were printed in PLA for about 30 cents each, while the finished TPU funnel costs $2-3 to produce, Branstetter said. The unit determined that no commercial product could match its design and maneuverability requirements, and that buying one would cost more than printing it in-house.

![McConnell AFB Innovation Lab 3D prints a fix for KC-46 engine servicing](https://www.voxelmatters.com/wp-content/uploads/2026/07/USAF-3D-printed-engine-funnel-03-340x252.jpg)

Branstetter said the same process could extend to other maintenance needs across the base.

“Almost any job can benefit from 3D printing. It's a cheap and convenient way to make readily available items to improve productivity,” he added.

The U.S. Army is turning increasingly towards 3D printing to solve issues such as the servicing of legacy parts no longer in production, [as well as on-the-field fast fixes](https://www.voxelmatters.com/us-armys-am-platoon-fabricates-counter-uas-mounts-in-the-field-during-flytrap-5-0/), and on a wider scale is scaling its adoption of additive manufacturing with [dedicated facilities such as the recently-opened Additive Makerspace at Picatinny Arsenal, New Jersey](https://www.voxelmatters.com/us-army-opens-am-facility-with-more-than-50-3d-printers/), which houses more than 50 3D printers.