Additive printing to help keep the USMC F-35 flying

Lockheed Martin F-35 Lightning II is a true marvel of modern times, and soon maintenance professionals will be using advanced technology to keep aircraft flying, namely additive or “3D” printing. The US Marine Corps has announced that it has begun special tools for printing used in the maintenance of the stealth fighter of the fifth generation.

Earlier this summer, Naval Aviation Squadron 13 personnel discovered there was a “critical shortage” of reamers, a precision cutting tool that is “essential to aviation maintenance” of the F-35. The tools are used by ground crews to ensure “proper fit and processing of composite materials and fasteners” on the Lightning II.

The problem was compounded by the fact that the tools were expensive to obtain, required long acquisition times, and had a limited lifespan. The fact is that sweeps should be produced by Torlona type of high-performance thermoplastic that can be safely used on an expensive stealth fighter, but it wears out quickly.

3D printing to the rescue

Instead of waiting for replacement sweeps to be made, Staff Sgt. Nicholas Bevan, an airframe technician, and Sgt. Landon Borodai, an aviation machinist, created his own custom sweep using additive printing. In addition to getting the tool you need lightning fast—from three months to the same day—the expanders produced by the two Marines can last 300 percent longer than conventionally manufactured, cutting maintenance costs nearly in half.

Instead of Torlon, the airframe technician and aviation machinist used chopped carbon fiber strands and high-temperature resin, which is stronger than the thermoplastic models.

“Torlon is a high-strength, highly abrasive material that won’t damage the aircraft structure, but is still abrasive enough to remove corrosion from the aircraft,” Bevan explained. “We used carbon fiber as an alternative to Torlon and as a 3D printing material to make these sweeps for our own assemblies.”

The two Marines also tweaked the design slightly, using Boroday’s computer aided design (CAD) expertise as well as his knowledge of 3D printing. A pair of Markforged X7 industrial 3D printers were used to print the tools in one day.

Significant cost savings

The printers have already been used to produce other key components, including “corrosion treatment mandrels and radius blocks,” but this was the first time a specific tool had been printed.

According to the USMC, this effort has already “saved MALS-13 over $10,000 in tooling,” and aircraft downtime for MAG-13 has also been reduced “by nearly 20% over a three-month period.”

“The versatility of these 3D printers is phenomenal,” Boroday said. “I got information on what type of scans the supply department was ordering, and I did the math and realized it might cost less if we printed them in-house.”

These techniques could be further used in the Marine Corps, and could even ensure that components can be manufactured in advanced environments as needed. The service acknowledged that the two Marines rose to the challenge and adapted accordingly.

“Staff Sergeant Bevan and Initiative Sergeant Boroday exemplify visionary innovation that directly enhances the readiness of 3rd MAW,” said Maj. Gen. James Wellons, commanding officer of 3rd MAW, who visited MALS-13 and recognized the efforts of the two Marines. awarding them both with orders. Navy and Marine Corps Achievement Medal.

“Their ability to develop solutions at the tactical level not only conserves resources, but also supports our aircraft’s mission readiness,” Wellons added. “Ingenuity like this keeps 3rd MAW at the forefront of operational excellence.”

Use 3D printing

This is far from the first case that the US military has has embraced additive printing. The services are already “printing” parts and components that are no longer in production, and the US Air Force is also using it to keep Northrop Grumman B-2 Spirit and Boeing B-52 Stratofortress bombers fly.

The Marine Corps has were used before HP’s Metal Jet 3D printer to produce components for its amphibious assault vehicles (AAVs), which first entered service in 1972. More recently, the US Navy and Marine Corps used 3D printing to produce cockpits for the F-35 Full Mission Simulator (FMS), an advanced high-fidelity flight simulator for training aviators on the Joint Strike Fighter.

The US military may not yet be at the point where they can just press Ctrl + P and see a jet fighter or even many components manufactured, but 3D printing will help ensure that the aircraft can continue to fly while reducing maintenance costs.

Author experience and expertise: Peter Suchu

Peter Suchiu is a writer from the state of Michigan. He has contributed to to more than four dozen magazines, newspapers and websites with more than 3,200 published pieces in a twenty-year career in journalism. He writes regularly on military technology, firearms history, cyber security, politics and international affairs. Peter also aContributing writer for Forbes and Customs clearance of works. You can follow him on Twitter:@PeterSuciu. You can write to the author by e-mail:(email protected).

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