U.S. Navy Tests 3D Printing to Accelerate Composite Repairs on F/A-18 Super Hornets
BY Composights
Published: 16 Jul 2026
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The U.S. Navy is evaluating a new 3D-printing-based composite repair process that could reduce repair times for F/A-18 Super Hornet aircraft by as much as 50%, helping improve fleet readiness while lowering maintenance costs.
The technology is being developed through a collaboration between the Fleet Readiness Center East (FRCE) and the Naval Air Warfare Center Aircraft Division (NAWCAD). The effort focuses on using additive manufacturing to produce customized repair tooling for damaged composite aircraft components, replacing conventional tooling that is often expensive and time-consuming to manufacture.
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Many structural components on modern military aircraft, including the F/A-18 Super Hornet, are made from advanced composites because of their lightweight and high-strength characteristics. However, repairing these components typically requires custom molds and fixtures that can take weeks to fabricate using traditional machining methods.
Under the new approach, engineers use 3D printers to rapidly manufacture repair tools, enabling maintenance teams to begin composite restoration much sooner. According to the Navy, the process has the potential to cut composite repair lead times in half, significantly reducing aircraft downtime.
The initiative is also expected to lower tooling costs while allowing maintenance personnel to produce repair solutions tailored to individual aircraft damage. By digitizing the tooling process, repair facilities can quickly modify or reproduce tools without the lengthy procurement cycles associated with conventional manufacturing.
The Navy believes the technology could improve sustainment of aging aircraft fleets while supporting faster return-to-service timelines for mission-critical platforms.
As military aircraft continue to incorporate larger proportions of composite structures, additive manufacturing is emerging as a valuable tool for maintenance, repair, and overhaul (MRO) operations, enabling more efficient repair of lightweight airframe components without compromising structural performance.
The ongoing testing highlights the growing role of digital manufacturing technologies in defense aviation, where reducing maintenance turnaround time is increasingly critical for improving aircraft availability and operational readiness.
