The Royal Air Drive (RAF) has efficiently fitted its first in-house 3D printed part to an operational Storm fighter jet. The transfer is a significant step towards sooner army plane repairs, permitting broken plane to return to service extra rapidly. And it was made doable by a Wayland Additive Calibur3 metallic 3D printer acquired by the RAF in 2022.
The set up occurred this week at RAF Coningsby, dwelling to the RAF’s Storm fleet. Engineers from 29 Squadron fitted a short lived alternative Anti-Yaw Spigot to Storm ZK309. Additionally identified in technical documentation as a “yaw spigot” or anti-rotation gadget, the Anti-Yaw Spigot is a part of the plane’s pylon meeting — the construction that connects weapons techniques to the wing. It helps hold that meeting secure and aligned beneath aerodynamic forces; mainly, it prevents undesirable twisting or yawing motions throughout flight, ensuring the weapons attachment level stays securely in place.
The becoming of the primary 3D printed half on a Storm ZK309.
The breakthrough was made doable by a collaboration between 29 Squadron engineers and No 71 Inspection & Restore (IR) Squadron. Based mostly on the RAF’s Hilda B. Hewitt Centre for Innovation, 71 Squadron makes a speciality of repairing structural harm to UK fixed-wing army plane and offering superior inspection capabilities. The unit additionally contains its personal design crew, which may create customized restore options when typical fixes are usually not out there or are impractical.
When the Storm part was broken, engineers scanned it and shared the information with each the unique producer, BAE Programs, and 71 Squadron. In keeping with the RAF, whereas the producer started work on a everlasting alternative, 71 Squadron designed and produced a short lived resolution utilizing superior 3D printing gear on the innovation centre.
“This isn’t supposed as a everlasting repair, nevertheless it reveals the place we’re heading,” stated Squadron Chief John Mercer, Senior Engineering Officer at No 29 Squadron. “When plane are grounded ready for spare components, we are able to’t afford delays. With the ability to print our personal non permanent parts means getting jets again within the air sooner.”
The restore course of confirmed the benefits of 3D printing for army upkeep. By producing components on-site, the RAF stated it will possibly keep away from the lengthy lead instances typically related to ordering from producers, particularly for older or specialised parts. This means can hold plane mission-ready in conditions the place time is important.
Wing Commander Gemma Lonsdale, Officer Commanding Air Wing Engineering at RAF Coningsby, famous: “This know-how presents monumental potential to keep up our plane sooner than ever earlier than. The 71 Squadron crew has been distinctive — their experience and collaboration made this milestone doable.”
The Hilda B Hewlett Centre for Innovation is provided with superior 3D printing and scanning know-how.
In a LinkedIn put up, Darrin Dickinson, head of enterprise improvement for EMEA at Wayland Additive, revealed that the half was produced utilizing the corporate’s Calibur3 metallic 3D printer. The Calibur3 makes use of Wayland’s proprietary NeuBeam electron beam melting course of to supply absolutely dense titanium parts with out cracking, and with out requiring further warmth remedy to alleviate stress or enhance mechanical properties.
In keeping with Dickinson, the RAF’s use of the Calibur3 to print a titanium half for the Storm represents a “important milestone for Wayland Additive within the aerospace and defence markets, and serves as a robust endorsement of the construct high quality produced by the corporate’s know-how.”
Whereas the half put in is just non permanent, having the ability to design and print parts in-house can get plane flying once more sooner, minimize prices by changing simply the damaged half as an alternative of the entire system, and hold jets able to go even when regular provide chains are gradual. The know-how also can assist when components are now not made or bought. In these instances, engineers can scan the outdated half, create a replica, and print it, avoiding the necessity to substitute a whole system.
For instance, within the case of the Storm’s pylon meeting, a standard alternative course of may contain super-long ready durations for producer deliveries, which may floor the plane for weeks and even months. As an alternative, a 3D printed non permanent half will be produced and put in in just some days, maintaining the plane in service till the everlasting half arrives.
Go to to RAF Coningsby by Director Help, Air Vice-Marshal S Harris CBE on Tuesday 5 August 2025.
The RAF’s success with this challenge almost certainly opens the door to wider adoption of additive manufacturing throughout its fleet, and expands the variety of repairs that may be made immediately by RAF engineers. As Squadron Chief Mercer famous, the top purpose is easy: “Getting jets again within the air sooner.” And that’s top-of-the-line makes use of for 3D printing.
Photos courtesy of the Royal Air Drive
Subscribe to Our E-mail Publication
Keep up-to-date on all the newest information from the 3D printing trade and obtain data and presents from third social gathering distributors.
Add your 3D Fashions and get them printed rapidly and effectively.
