First RAF-Made 3D Printed Part Installed on Operational Typhoon Jet
In a new development within the defense sector, the United Kingdom’s Royal Air Force has successfully installed its first in-house manufactured 3D printed component to an operational Typhoon fighter jet at RAF Coningsby. This is a new milestone that signals a transformative leap in aircraft maintenance, promising faster repairs and reduced downtime for the military fleet.
Engineers were able to install a temporary 3D printed replacement part for the pylon assembly. This is the structure that connects the weapons system to the aircraft’s wing. The part itself was designed and produced at the Hilda B. Hewitt Centre for Innovation by scientists from No. 71 Inspection & Repair Squadron. These parts were then installed and fitted by members of the 29 Squadron.
The Senior Engineering Officer at No 29 Squadron, John Mercer, highlighted the significance of this new development by stating, “This isn’t intended as a permanent fix, but it shows where we’re heading. When aircraft are grounded waiting for spare parts, we can’t afford delays. Being able to print our own temporary components means getting jets back in the air faster.”
The repair process for the new part was incredibly efficient. First, the damaged part was precision-scanned using laser imaging. The data was then shared simultaneously with the original manufacturer and 71 Squadron. The manufacturer was able to start on a new permanent replacement part, while the team at 71 Squadron designed and printed an intermediate component to allow the aircraft to continue to operate. This helped demonstrate the potential rapid response of additive manufacturing in the defense sector.
No. 71 Inspection & Repair Squadron is a part of the RAF Support Force. They play a vital role in repairing damaged structures on many UK fixed-wing military aircraft. The squadron’s unique capability includes designing new repair solutions where traditional methods are impractical or unavailable.
Wing Commander Gemma Lonsdale praised the team’s efforts by noting, “This technology offers enormous potential to maintain our aircraft faster than ever before. The 71 Squadron team has been exceptional—their expertise and collaboration made this milestone possible.” This pioneering first step is set to unlock broader applications across the RAF’s fleet, with benefits including reduced maintenance costs and improved aircraft availability for operational commitments.
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*All Photo Credit: Royal Air Force United Kingdom
