FRCE Just 3D Printed Its First Flight-Certified Metal Parts and Put Them on Active Aircraft

Why It Matters

Rapid, certified 3D‑printed parts cut logistics lead times, boosting fleet readiness and operational availability for the U.S. military.

Key Takeaways

• FRCE printed first flight‑certified metal parts in‑house.
• Certification completed in under six months, NAVAIR record.
• Parts deployed on AH‑1Z, V‑22, C‑130 platforms.
• Program aims to add stainless‑steel capability for more critical components.
• On‑demand printing reduces logistics bottlenecks across DoD supply chain.

Pulse Analysis

Additive manufacturing has moved from experimental labs to the front lines of military logistics, and FRCE’s recent milestone underscores that shift. By printing metal brackets and fittings on‑site, the depot eliminated the traditional wait for external suppliers, delivering flight‑certified components in weeks rather than months. The collaboration with NAVAIR’s Additive Manufacturing Team ensured that the parts met the same rigorous safety standards as legacy production, proving that 3D‑printing can satisfy the exacting demands of combat‑rated aircraft.

The six‑month certification timeline—covering design validation, material testing, and airworthiness approval—sets a new benchmark for the Department of Defense. FRCE’s first certified part, a pylon fitting for the AH‑1Z Viper, was quickly followed by a landing‑gear repair fitting for the V‑22 Osprey and a blanking plate for the C‑130 Hercules. These non‑flight‑critical components already demonstrate measurable reductions in aircraft downtime, and the planned expansion to stainless‑steel parts promises to address higher‑stress, flight‑critical applications, further shrinking the logistics gap.

Beyond the immediate operational gains, FRCE’s success signals a broader transformation in defense procurement. Federal initiatives such as the $8.8 million Oklahoma‑Oak Ridge partnership and the $1.7 million America Makes funding call are accelerating the qualification of additive‑manufactured parts across the DoD. As more depots adopt on‑demand printing, the traditional part‑by‑part qualification bottleneck could dissolve, enabling a more resilient, responsive supply chain that keeps legacy aircraft flying longer and at lower cost.