Military Aircraft Undergoes Testing With Additively Manufactured Parts

Additively manufactured hardware produced under the AMNOW Program recently underwent flight testing on operational aircraft. Two additively manufactured (3D printed) cargo links were installed on two operational MH-47G aircraft at Fort Campbell, Kentucky, in support of an extended flight test program.

The cargo links were manufactured from a high-strength aluminum alloy 7A77 under NCDMM’s AMNOW program and represent the first Army-developed metallic AM aircraft parts to be flown on Army aircraft.

NCDMM with its National Additive Manufacturing Innovation Institute, America Makes and partner Catalyst Connection launched the AMNOW program in 2019 to support additive manufacturing (AM) technology insertion into the existing U.S. Army supply chain. Structured as a potentially multiphase, multiyear contract, AMNOW is funded by the U.S. Army Combat Capabilities Development Command (DEVCOM) – Aviation & Missile Center through the U.S. Army Manufacturing Science and Technology (MS&T) Division under U.S. Army Futures Command.

AMNOW projects are working to integrate and accelerate the dissemination, transition and use of innovative, crosscutting AM technologies for the Army to enhance operations. By enabling a robust AM supply chain and clear technology AM transition path, AMNOW aims to help increase the U.S. Army’s readiness and facilitate on-demand production of materials in support of warfighters and commanders on the battlefield.

For this testing, the AMNOW program team and the U.S. Army Combat Capabilities Development Command (DEVCOM) Aviation and Missile Center (AvMC) were supported by key suppliers. The 7A77 powder was treated and supplied by HRL of Malibu, California. Printing was provided by Beehive Industries (formerly Volunteer Aerospace) of Knoxville, Tennessee. Machining and finishing was performed by Penn United Technologies of Cabot, Pennsylvania. Material testing was provided by Product Evaluation Systems of Latrobe, Pennsylvania, while radiographic inspection was performed by Pinnacle Industrial X-ray Laboratory of Suwanee, Georgia.

The AMNOW program team consists of NCDMM, The Barnes Global Advisors, Youngstown Business Incubator, Catalyst Connection, LECS Energy, Quotient, Advanced Engineering Solutions, GCA Coach and the University of Alabama-Huntsville.