The project uses an innovative digital twin of the aircraft, developed by NIAR since early 2020. Researchers disassembled and scanned two retired B-1s to create detailed 3D models, which have now been applied to design and build the replacement fuselage section for installation on an operational bomber.
“The digital twin allows for more efficient manufacturing of parts, reduces errors, and facilitates better collaboration between engineers and technicians,” said Joe Stupic, Senior Material Leader and Division Chief of the B-1 Program Office, within the Air Force Life Cycle Management Center. “Because of our work using digital technology, I believe we can get the aircraft in and out of the [NIAR] hangar in under a year, which will be a significant cost savings for the Air Force.”
The approach is designed to save time and reduce costs compared with traditional methods of repair. It also demonstrates how digital techniques can provide sustainable solutions for ageing military aircraft.
“Digital is definitely taking us on a lot of twists and turns of journeys that I didn’t expect,” said Dr. Melinda Laubach-Hock, NIAR Director of Sustainment. “Certainly landing an operational B-1 at a university facility seems like a crazy idea, but we’ve been able to prove we can execute this repair. We appreciate the trust and willingness from the Air Force B-1 Program Office, and Air Force Global Strike Command to work with us in executing the repair on this aircraft.”
