Aging aircraft compounded by maintainer supply shortages have resulted in a diminution in readiness and lethality amongst aircraft weapon systems and a limitation to operational agility due to reliance on commercial supply chains for critical replacement parts and limited ability to quickly and effectively prototype, test, and deploy custom parts for aging and state-of-the-art aircraft systems This proposal will develop and validate additive manufacturing processes using halloysite- and nylon-based and/or enhanced replacement, custom, and OEM aircraft parts. Fully validated, these parts will possess a higher burn point and greater durability compared to current solutions and will be able to be produced by AF maintainers on site as needed within base 3D printer facilities. This technology will increase readiness & lethality of aging aircraft systems via superior, 3D printed replacement parts, provide a more stable & more agile supply chain fully under control of USAF, and deliver a repeatable and reliable ideation, testing, and deployment methodology for developing and 3D printing custom aircraft parts on demand.
