Broad Spectrum Additive at the US Air Force

If we look at how Air Forces around the world use additive manufacturing, a lot of the attention is focused on future possibilities in hypersonics and next-generation aircraft. Beyond the rosy future scenarios, though, there is quite a lot going on already in maintenance. Across several major bases, the US Air Force is saving millions by 3D printing tooling, making high-tech coverings, aerodynamic fairings, and 3D printing circuit boards. All of these cases illustrate what a broad spectrum adoption of Additive can do for MRO (maintenance, repair, and overhaul) while also showcasing the improvisational possibilities of Additive to solve many problems differently.

The Air Force has gained deeper 3D printing experience, training, and a thorough understanding, and this lets them adequately deploy the technology across many different cases. We would expect many more aircraft maintenance organizations to adopt similar programs in the future.

Feature image: U.S. Air Force Senior Airman Sean Ellis explains 3D printing capabilities during the Innovation Oasis III Roadshow within the U.S. Central Command area of responsibility on Feb. 6, 2025. Image courtesy of U.S. Air Force/Senior Airman Violette Hosack.