Navy’s 3D printing could halve Super Hornet composite repair time by 2026
The U.S. Naval Air Warfare Center Aircraft Division (NAWCAD) has developed a 3D-printed composite patch repair method for F/A-18 Super Hornets that could cut repair time by 50%. The patches enable sailors to perform complex fixes at forward operating bases, eliminating the need to ship parts back to U.S. depots. After successful lab and ground tests, flight tests are scheduled for summer 2026. Currently, 22 Navy maintenance sites worldwide have 3D printers, supporting rapid forward repairs. The innovation coincides with the Marine Corps’ planned phase-out of Hornet squadrons by 2030.
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Navy's 3D printing could cut Super Hornet composite repair time by 50%
The Naval Air Warfare Center Aircraft Division (NAWCAD) has developed a groundbreaking 3D-printed composite patch repair method for F/A-18 Super Hornets that could reduce repair time by 50%. The patches can be applied directly onto aircraft at forward operating bases, eliminating the need to ship damaged parts back to U.S. repair depots. This enables sailors to perform complex composite fixes without specialized maintenance artisans, improving operational readiness. After successful lab and ground tests, flight tests on operational aircraft are scheduled for summer 2026. Currently, 22 Navy maintenance sites worldwide already have 3D printers, potentially allowing swift repairs where aircraft operate. The development comes as the Marine Corps phases out Hornet squadrons by 2030 in favor of an all-F-35 fleet.
Navy TimesTime spent on select Super Hornet repairs could be cut in half with Navy’s 3D printing
The Naval Air Warfare Center Aircraft Division (NAWCAD) has developed a groundbreaking 3D-printed composite patch repair method for F/A-18 Super Hornets that could cut repair time by 50%. The method allows sailors to perform complex composite fixes at forward operating bases, eliminating the need to ship parts back to U.S. depots and reducing aircraft downtime. A joint team from NAWCAD and Fleet Readiness Center Southwest created the patches. After successful lab and ground tests, flight tests on operational aircraft are set to begin in summer 2026. This innovation comes as the U.S. Marine Corps plans to deactivate all remaining Hornet squadrons by 2030 and transition to an all-F-35 fleet. Currently, 22 Navy maintenance sites worldwide already have 3D printers, enabling potential rapid forward-deployed repairs.
Military TimesNavy's 3D printing could cut Super Hornet composite repair time in half
The Naval Air Warfare Center Aircraft Division (NAWCAD) has developed a 3D-printed composite patch method that could reduce F/A-18 Super Hornet repair time by 50%. The patches can be applied directly at forward operating bases, eliminating the need to ship damaged aircraft or parts back to US depots. This innovation aims to improve fleet self-sufficiency and operational readiness. After successful lab and ground tests, flight tests on operational aircraft are scheduled for summer 2026. The US Marine Corps is concurrently phasing out older Hornet squadrons by 2030 as it transitions to an all-F-35 fleet. Currently, 22 Navy maintenance sites worldwide already possess 3D printers, enabling rapid deployment of this repair capability.
Military TimesTime spent on select Super Hornet repairs could be cut in half with Navy’s 3D printing
The U.S. Naval Air Warfare Center Aircraft Division (NAWCAD) is testing a groundbreaking 3D-printed composite patch repair method for F/A-18 Super Hornets that could cut repair time by 50%. The patches allow sailors to perform complex composite fixes at forward operating bases, eliminating the need to ship damaged parts back to U.S. depots. NAWCAD Commander Rear Adm. Todd Evans said the goal is to improve fleet self-sufficiency and operational readiness. A joint team from NAWCAD and Fleet Readiness Center Southwest developed the patches. After successful lab and ground tests, flight tests on operational aircraft are scheduled for summer 2026. Currently, 22 Navy maintenance sites worldwide already have 3D printers, enabling swift forward repairs. The development comes as the Marine Corps plans to phase out all Hornet squadrons by 2030 in favor of an all-F-35 fleet.
Navy TimesNavy's 3D printing could halve repair time for F/A-18 Super Hornet composite damage
The Naval Air Warfare Center Aircraft Division (NAWCAD) announced a new 3D-printing repair method that could cut composite repair time for F/A-18 Super Hornets by 50%. The method uses high-performance 3D-printed composite patches applied directly onto the aircraft, enabling sailors to perform complex fixes at forward operating bases without needing specialized maintenance artisans or lengthy turnaround times. This reduces the need to ship parts back to U.S. depots, improving operational readiness. After successful lab and ground tests, flight tests on operational aircraft are set to begin in summer 2026. Currently, 22 Navy maintenance sites worldwide already have 3D printers, potentially allowing swift repairs where aircraft operate. The development comes as the U.S. Marine Corps phases out Hornet squadrons by 2030 in favor of an all-F-35 fleet.
Military TimesNavy's 3D printing could halve repair time for F/A-18 Super Hornet composite repairs
The Naval Air Warfare Center Aircraft Division (NAWCAD) has developed a groundbreaking 3D-printed composite patch repair method that could cut F/A-18 Super Hornet composite repair time by 50%. The patches can be applied directly onto aircraft at forward operating bases, eliminating the need to ship damaged parts back to U.S. depots and reducing lengthy turnaround times. A joint team from NAWCAD and Fleet Readiness Center Southwest created the patches, which have passed lab and ground tests. Flight tests on operational aircraft are scheduled for summer 2026. NAWCAD Commander Rear Adm. Todd Evans stated the goal is to make squadrons more self-sufficient and improve operational readiness. Currently, 22 Navy maintenance sites worldwide already possess 3D printers, enabling swift forward repairs. The development comes as the Marine Corps phases out Hornet squadrons by 2030 in favor of an all-F-35 fleet.
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