25007 – Strong Parts for Expeditionary Repair of Aircraft Structural Components

Strong Parts for Expeditionary Repair of Aircraft Structural Components

Expeditionary Repair of aircraft structural components

Problem: Aircraft sustainment in expeditionary environments faces challenges from supply chain delays, lack of specialized tooling, and the need for rapid, reliable part replacements. Traditional repair methods are often time-consuming and require access to extensive resources. A deployable, efficient, and robust solution is critical to maintaining operational readiness. Most additive manufacturing solutions do not produce parts strong enough to be used for end use or structural parts.

Description: Markforged’s Continuous Carbon Fiber (CCF) reinforcement in Onyx and Vega materials provides a portable, field-ready solution for producing strong, durable, end-use parts. The Markforged X7 Field Edition is designed for rugged, expeditionary environments, enabling immediate part production at the point of need. CCF-reinforced Onyx offers aluminum-comparable strength for structural applications, while Vega provides exceptional high-temperature and chemical resistance, making it ideal for aerospace components. This solution reduces reliance on traditional supply chains and minimizes downtime.

Benefits: Operational Readiness: On-demand part production ensures mission-critical repairs without waiting for external logistics.

Cost Savings: Reduces transportation and procurement costs by eliminating the need to stockpile parts. Less expensive to manufacture the parts on demand than ordering parts from the OEMs.

Enhanced Durability: Continuous Carbon Fiber (CCF)-reinforced Onyx material delivers parts with a tensile strength of 800 MPa, rivaling aluminum in structural integrity. First in class strength to produce parts that are Army Strong.

Aerospace-Grade Materials: Vega’s high-temperature tolerance (>230°C) and chemical resistance make it suitable for engine components and other extreme environments.

Portable and Energy Efficient: The X7 Field Edition operates using 400-600 watts, enabling off-grid use via solar or generator power.

Ease of Use: One click printing for simple training and deployment of solutions.

Innovation Challenges: Material Qualification: Efforts are underway to align CCF, Onyx and Vega with military certification standards. Currently, the Navy & Marines use these materials, but adoption across the Army and Air Force has taken more time.

Interoperability: Integration of our digital inventory system with existing military logistics platforms is our long-term goal, which will allow OEM’s to upload files for easy click printing in the DOD downrange. FedRAMP is a process we are working through and currently offer Offline software to support DOD missions with the goal of FedRAMP long term.

Maturity/Results: Markforged solutions are currently at TRL 7, with FAA certified B-basis allowables dataset for our materials. The US Navy has tested and adopted the use of our X7 solution shipboard.