US Navy aims to cut F/A-18 composite repair times in half with 3D printed patches
Flight tests planned for this summer at forward operating bases
The US Navy is testing a 3D printed composite patch repair method it said could cut F/A-18 Super Hornet repair times by roughly 50%, with plans to flight-test the process on an operational aircraft this summer.
The Naval Air Warfare Center Aircraft Division (NAWCAD) and Fleet Readiness Center Southwest (FRCSW) developed the repair approach to let sailors fix damaged composite parts, such as engine bay doors, directly at forward operating bases rather than shipping aircraft or parts back to depots in the United States.
“Our goal is to put capability directly into the hands of the Fleet,” said NAWCAD Commander Rear Adm. Todd Evans. “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.”
From lab to flight line
The 3D printed patch method completed lab and ground testing before the joint NAWCAD-FRCSW team moved to flight testing. When an F/A-18 is grounded with damaged composite components, the aircraft becomes unavailable for missions; repairing the material traditionally has required specialized maintenance personnel and turnaround times long enough to strain supply chains and squadron availability.
To address the delays, NAWCAD and FRCSW engineers designed high-performance 3D-printed composite patches for direct application to the aircraft, along with patch application procedures and quality checks intended to confirm the printed parts meet flight-safety requirements.
Forward-deployed printer network
The repair method is intended to draw on 3D printers already placed at 22 Navy maintenance sites worldwide, allowing repairs where aircraft operate rather than routing parts through depot-level facilities in the US
NAWCAD, based in Patuxent River, Maryland, with additional sites in St. Inigoes, Maryland; Lakehurst, New Jersey; and Orlando, Florida, supports test, evaluation, research, development and sustainment work for Navy and Marine Corps aviation platforms. FRCSW, based in San Diego, is one of naval aviation’s major maintenance facilities.
