en.Wedoany.com Reported - The Naval Air Warfare Center Aircraft Division (NAWCAD) and the Fleet Readiness Center Southwest (FRCSW) have jointly developed a 3D printing repair method aimed at reducing the composite repair time for the F/A-18 Super Hornet by approximately 50%. This method enables sailors to perform repairs directly at forward operating bases, eliminating the need to transport damaged components back to depot-level maintenance facilities.

When an F/A-18 is grounded due to damage to composite components, such as engine bay doors, the Navy loses critical combat capability. Traditional repair processes require highly specialized maintenance technicians and lengthy turnaround times, keeping aircraft out of service and extending the supply chain. To address this challenge, engineers from NAWCAD and FRCSW developed high-performance 3D-printed composite patches that can be directly applied to aircraft. The team also established patch application procedures and quality inspection standards to ensure these printed parts are safe for flight.

This solution will benefit from a network of 3D printers already deployed at 22 naval maintenance sites worldwide, enabling repairs to be performed locally where aircraft are actively operating. Following successful laboratory and ground tests, the joint development team plans to conduct flight tests of the 3D-printed repairs on an active aircraft in the summer of 2026.

Rear Admiral Todd Evans, Commander of NAWCAD, stated that the goal is to put the capability directly into the hands of the fleet. By simplifying complex repair processes so they can be completed forward, engineers can return aircraft to combat more quickly, making squadrons more self-sufficient and directly enhancing readiness. NAWCAD's primary bases are located in St. Inigoes, Maryland; Lakehurst, New Jersey; and Orlando, Florida, while FRCSW is one of the Navy's major aviation maintenance facilities based in San Diego.