U.S. Air Force Robot Fabricates Unobtainable C-17 Part, Returns Aircraft to Service
In March 2025, severe storms at Perot Field Fort Worth Alliance Airport, Texas, pushed two private jets into a U.S. Air Force C-17 Globemaster III, damaging its left nose panel, door, and fuselage. Boeing could not find a vendor to produce tooling for a single replacement panel, threatening a two-year grounding. The Air Force Rapid Sustainment Office, with the University of Dayton Research Institute, used incremental sheet forming (ISF) robot technology to fabricate the part. Production began in January 2026, and the panel was installed in July 2026. The C-17 flew again on July 30, 2026, marking the first incrementally formed part to fly on an Air Force aircraft.
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Air Force Robot Produces Unobtainable C-17 Part, Returns Aircraft to Service
A U.S. Air Force C-17 Globemaster III (tail number 01-0194) from the 445th Airlift Wing at Wright-Patterson Air Force Base was severely damaged in March 2025 when severe storms pushed two private jets into it at Perot Field Fort Worth Alliance Airport. The collision damaged the left nose panel, door, and fuselage. Boeing could not find a vendor to produce tooling for a single replacement nose panel, threatening a two-year grounding. The Air Force Rapid Sustainment Office (RSO) used incremental sheet forming (ISF) technology—a robot pressing metal into shape without molds—to fabricate the part. Working with the University of Dayton Research Institute, production began in January 2026. Boeing and wing maintainers installed the panel in July 2026, and the aircraft flew again on July 30, 2026, after 17 months. This is the first incrementally formed part to fly on an Air Force aircraft. The RSO is now working on parts for KC-135 and F-15 aircraft.
U.S. Air Force Robot Fabricates Unobtainable C-17 Part, Returns Aircraft to Service
A U.S. Air Force C-17 Globemaster III (tail number 01-0194) from the 445th Airlift Wing at Wright-Patterson Air Force Base, Ohio, was severely damaged in March 2025 when severe storms pushed two private jets into it at Perot Field Fort Worth Alliance Airport, Texas. The collision damaged the left nose panel, door, and fuselage. Boeing could not find a vendor to produce tooling for a single replacement nose panel, leading to a projected two-year grounding. The Air Force Rapid Sustainment Office (RSO), working with the University of Dayton Research Institute, used incremental sheet forming (ISF) technology—a robot pressing metal into shape without molds—to fabricate the part. Production began in January 2026, and the panel was installed in July 2026. The aircraft flew again on July 30, 2026, after nearly 17 months. This marks the first incrementally formed part to fly on an Air Force aircraft. The RSO is also working on parts for KC-135 and F-15 aircraft.
U.S. Air Force Robot Produces Unobtainable C-17 Part, Returns Aircraft to Service
A U.S. Air Force C-17 Globemaster III (tail number 01-0194) from the 445th Airlift Wing at Wright-Patterson Air Force Base, Ohio, was severely damaged on March 4, 2025, when severe storms pushed two private jets into it at Perot Field Fort Worth Alliance Airport, Texas. The collision damaged the left nose panel, door, and fuselage. Boeing could not find a vendor to build tooling for a single replacement nose panel, threatening to sideline the aircraft for two years. The Air Force Rapid Sustainment Office (RSO) used incremental sheet forming (ISF) technology, where a robot presses a flat metal sheet into shape without molds, to produce the part. Working with the University of Dayton Research Institute, production began in January 2026. Boeing and wing maintainers installed the finished panel in July 2026, and the aircraft flew again on July 30, 2026, nearly 17 months after the storm. This marks the first incrementally formed part to fly on an Air Force aircraft.
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U.S. Air Force robot builds C-17 part no vendor would supply
A U.S. Air Force C-17 Globemaster III (tail number 01-0194) from the 445th Airlift Wing at Wright-Patterson Air Force Base was damaged on March 4, 2025, when severe storms at Perot Field Fort Worth Alliance Airport in Texas caused two private Bombardier Challenger jets to collide with it. The collision damaged the left nose panel, fuselage, and door. After Boeing could not find a vendor to build tooling for a single nose panel, the aircraft faced a two-year repair delay. The Air Force Rapid Sustainment Office (RSO) used incremental sheet forming (ISF) technology, where a robot presses a flat metal sheet into shape without molds, working with the University of Dayton Research Institute. Production began in January 2026, and the panel was installed in July 2026. The C-17 flew again on July 30, 2026, nearly 17 months after the storm. This marks the first incrementally formed part to fly on an Air Force aircraft. The RSO is also working on parts for a KC-135 and an F-15.
Air Force Robot Produces Unobtainable C-17 Part, Returns Aircraft to Service
A U.S. Air Force C-17 Globemaster III (tail number 01-0194) from the 445th Airlift Wing at Wright-Patterson Air Force Base, Ohio, was severely damaged in March 2025 when severe storms pushed two private Bombardier Challenger jets into it at Perot Field Fort Worth Alliance Airport, Texas. The collision damaged the left nose panel, door, and fuselage. Boeing could not find a vendor to build tooling for a single replacement nose panel, threatening to sideline the aircraft for two years. The Air Force Rapid Sustainment Office (RSO) at Wright-Patterson, working with the University of Dayton Research Institute, used incremental sheet forming (ISF) technology—where a robot presses metal into shape without molds—to produce the part. Production began in January 2026, and Boeing and maintainers installed the finished panel in July 2026. The aircraft flew again on July 30, 2026, nearly 17 months after the storm. This marks the first incrementally formed part to fly on an Air Force aircraft, highlighting a solution for aging fleets like the C-17, which the Air Force plans to fly into the 2070s.
U.S. Air Force Robot Fabricates Unobtainable C-17 Part, Returns Aircraft to Service
A U.S. Air Force C-17 Globemaster III (tail number 01-0194) from the 445th Airlift Wing at Wright-Patterson Air Force Base was severely damaged in March 2025 when severe storms pushed two private jets into it at Perot Field Fort Worth Alliance Airport. The collision damaged the left nose panel, door, and fuselage. While the door and fuselage were repaired, Boeing could not find a vendor willing to build tooling for a single nose panel, leaving the aircraft facing two years out of service. The Air Force Rapid Sustainment Office (RSO) stepped in, using incremental sheet forming (ISF) technology with a robot to press a flat metal sheet into shape without molds. Working with the University of Dayton Research Institute, production began in January 2026. Boeing and wing maintainers installed the finished panel in July 2026, and the C-17 flew again on July 30, 2026, after 17 months. This marks the first incrementally formed part to fly on an Air Force aircraft. The RSO is now working on parts for KC-135 and F-15 aircraft.