US Air Force uses robot to build C-17 part, repairing storm-damaged aircraft

Published Aug 6, 09:31 PM UTC

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.