The method is designed to allow sailors to perform composite repairs directly at forward operating bases. The Navy said the approach would help return aircraft to service faster and reduce reliance on longer repair chains.
“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.”
After successful laboratory and ground tests, the joint development team plans to flight-test the 3D-printed repair on an operational aircraft this summer. The work focuses on composite components that can ground F/A-18 aircraft when damaged, including engine bay doors.
The Navy said traditional repair of these advanced materials can cause severe delays. The process has historically required highly specialized maintenance artisans and lengthy turnaround times, keeping jets out of the air and stretching supply chains.
To address the issue, NAWCAD and FRCSW engineers created high-performance, 3D-printed composite patches that can be applied directly onto the aircraft. The team also developed patch application procedures and quality checks to ensure the printed parts are safe for flight.
The solution could use a network of 3D printers already deployed at 22 Navy maintenance sites around the world. That network would allow repairs where aircraft are actively operating, rather than waiting for parts to be shipped back to repair depots in the United States.
NAWCAD operates test ranges, laboratories and aircraft in support of test, evaluation, research, development and sustainment for Navy and Marine Corps aviation platforms. The command is based in Patuxent River, Maryland, with major sites in St. Inigoes, Maryland, Lakehurst, New Jersey, and Orlando, Florida.
FRCSW is one of naval aviation’s major maintenance facilities and is based in San Diego. The repair initiative links NAWCAD’s engineering and test work with FRCSW’s naval aviation maintenance role.
