en.Wedoany.com Reported - The US Navy plans to conduct flight tests this summer on an active-duty F/A-18 Super Hornet using a 3D printed composite patch repair method, which is said to reduce maintenance time by approximately 50%.
Developed jointly by the Naval Air Warfare Center Aircraft Division (NAWCAD) and the Fleet Readiness Center Southwest (FRCSW), this repair method enables sailors to directly repair damaged composite components (such as engine bay doors) at forward operating bases, eliminating the need to transport the aircraft or parts back to depots in the continental United States.
Rear Admiral Todd Evans, Commander of NAWCAD, stated that the goal is to empower the fleet directly by simplifying complex maintenance procedures so they can be completed at forward bases, allowing engineers to return aircraft to combat faster—a smart approach that makes squadrons more self-sufficient and directly enhances readiness levels.
This 3D printed patch method has been validated in laboratories and on the ground, after which the NAWCAD-FRCSW joint team moved to the flight test phase. F/A-18s are unable to perform missions when grounded due to damaged composite components; traditional repair methods rely on specialized maintenance personnel and have long turnaround times, putting pressure on the supply chain and squadron availability. To address this issue, engineers designed high-performance 3D printed composite patches that can be directly applied to the aircraft, and developed installation procedures and quality inspection processes to ensure printed parts meet flight safety standards.
The repair plan leverages 3D printers already deployed at 22 naval maintenance sites worldwide, enabling repairs to be completed locally in the aircraft's operational area without requiring transit through depot-level facilities in the continental United States.
NAWCAD, headquartered at Patuxent River, Maryland, with branches in St. Inigoes, Maryland; Lakehurst, New Jersey; and Orlando, Florida, is responsible for testing, evaluation, research and development, and support of Navy and Marine Corps aviation platforms. FRCSW, located in San Diego, is one of the Navy's primary aviation maintenance facilities.
