University of Oklahoma and ORNL launch Phase II of Air Force AM program
The $8.8 million initiative targets standardized qualification framework for 3D printed parts on legacy aircraft, and builds on establishment of cutting-edge additive manufacturing center
The University of Oklahoma and Oak Ridge National Laboratory (ORNL), in partnership with the Air Force Sustainment Center (AFSC), Air Force Research Laboratory (AFRL), and the Oklahoma City Air Logistics Complex (OC-ALC), have launched Phase II of an additive manufacturing research program that is aimed at streamlining how the US military maintains legacy aircraft.
Military aircraft that can remain in service for upwards of 60 years require replacement parts that are increasingly difficult to source, and the program is attempting to address this persistent challenge.
Current airworthiness certification requires the materials, geometry, and machines used in additive manufacturing to be tested individually, making part qualification both cost and time-intensive.
The new approach will digitally track the entire manufacturing process as a single data stream, enabling parts to be produced across various machines and platforms while still meeting military safety requirements.
“Phase I focused on replacement components using additive manufacturing, especially laser powder bed fusion,” stated Zahed Siddique, Associate Dean of Research in the Gallogly College of Engineering at OU. “In Phase II, we will be looking at the repair of components in addition to the manufacturing of new components and looking at quality assurance using AI and in situ monitoring.”
The project also draws on ORNL capabilities, including the Peregrine software platform, which supports quality monitoring during 3D printing.
“Sustainment is extremely important to the readiness of our US Air Force and broader Department of War,” said Moe Khaleel, Associate Laboratory Director for National Security Sciences at ORNL.
“We are proud to partner with the University of Oklahoma and the Air Force to democratize national laboratory capabilities — like the Peregrine software — which can accelerate manufacturing innovation and ultimately build defect-free parts that are born ready to fly.”
The program runs through 2028 and aims to establish a single standardized qualification process across the AFSC, OC-ALC, and their respective supply chains.
“Standardizing additive manufacturing qualification is a pervasive issue in the aerospace industry,” said Mark Benedict, Senior Scientist for Convergent Manufacturing at AFRL. “The work that the OU-ORNL partnership is accomplishing accelerates the technology’s adoption for our sustainment enterprise.”
OU was awarded $8.8 million as part of the initiative.
