Travis Air Force Base, Calif., claims mechanics from the 60th Maintenance Squadron and the 349th Aircraft Maintenance Squadron, and engineering and contracting from the C-5 Systems Program Office at Robin AFB, Ga. Suppliers, jointly using 3D printing technology, completed the maintenance of the internal and external components of C-5M Super Galaxy.
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△The pilots of the 60th and 349th Maintenance Squadrons are preparing for the C-5M Super Galaxy before maintenance, including the maintenance of the wing surface. The C-5M Super Galaxy is outfitted with newly 3D-printed parts, including parts called "blocks" and "wedges"
The blocks and wedges mentioned in the picture above are all critical components used to repair and maintain the surface of the wing of the C-5M Super Galaxy aircraft. These 3D printed parts can replace parts made by traditional processing and manufacturing methods, so it has higher efficiency and lower cost when repairing and maintaining the C-5M Super Galaxy aircraft.
In addition, according to Clay Elliott, C-5 structural engineering expert of C-5 SPO, the printing blocks and wedges provided by the U.S. Air Force Rapid Maintenance Office can be used for the aerodynamic cover on the wing of the C-5 model Provide better support effect. The aerodynamic cover is to help reduce the aerodynamic force and drag generated by the aircraft when flying at high speed.
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△C-5M Super Galaxy Transport Aircraft Schematic
Installing 3D printed parts for the C-5M
In December, after a Travis Air Force Base C-5M arrived at Charleston Air Force Base in South Carolina during its descent, the crew discovered a part of a hump-shaped aerodynamic shroud panel was missing during a post-flight inspection.
"When the technicians went on the wing, they found that one of the polymer composite materials, phenolic [blocks], was heavily delaminated," Elliott said. Those structures were on the verge of complete failure, thus rendering the aircraft unable to continue its mission.
In order to restore the aircraft as quickly as possible, Elliott proposes to integrate 3D printed parts made of the new thermoplastic material Antero 800NA into aircraft repairs.
So the U.S. Air Force team conducted a test of 3D printed parts for the C-5M at Hill Air Force Base in Utah, and used six different 3D printed parts in the test, all of which were replacing traditionally manufactured parts. These parts are made of composite materials that can withstand high temperatures and pressures, while still being very lightweight. The rapid manufacturing process of these parts greatly shortens the manufacturing cycle and also saves costs. Components manufactured using 3D printing can not only be produced in a short time, but are also more environmentally friendly due to less material waste.
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△In addition, laser metal deposition 3D printing technology aims to shorten the waiting time for spare parts, reduce maintenance downtime, and improve aircraft availability and combat readiness in terms of component maintenance and manufacturing
Solving the Supply Chain Problems of Rapid Aviation Repairs
In tests, the C-5M successfully flew for 45 hours using these 3D printed parts, proving that these parts can meet the operational requirements of the C-5M. The successful application of 3D printing parts will allow the Air Force to quickly manufacture parts when needed without having to rely on traditional manufacturing methods, which will improve the availability and operational efficiency of Air Force aircraft.
"The 3D printed Antero material seems to be a solid alternative to phenolics for the work we do," Elliott said. "So far, we've had no problems with any of the aircraft we've repaired using these improved materials and processes. question."
60th MXS Director of Aircraft Structural Maintenance Todd Hicks highlighted how the new technology has sped up repair and restoration work on some C5-Ms. If parts are not available locally, it gives the 60 MXS the option to produce certain parts on demand rather than having to go through the lengthy process of sourcing parts from third parties. This method of integrating 3D printing technology has resulted in faster turnaround times and reduced costs.
This test also verified the extensive application prospects of 3D printing technology in the military field. In the future, with the continuous advancement of technology and the expansion of applications, 3D printing technology will play an increasingly important role in the military field.
