US Air Force Uses 3D Printing To MQ-9 Maintenance Training

The 432nd Wing leverages additive manufacturing to revolutionize MQ-9 Reaper maintenance training with cost-effective 3D-printed parts.

At Creech Air Force Base in Indian Springs, Nevada, the 432nd Wing has discovered an unexpected solution to maintenance training challenges: 3D printing. The 432nd Maintenance Group’s Engineering and Technical Services (AFETS) team has implemented an additive manufacturing program that promises to transform how maintenance personnel train on unmanned aerial vehicles.

The initiative began when MQ-9 AFETS supervisor Kennon Nichols and 432nd Maintenance Group Commander Colonel Joseph Deporter secured funding for two 3D printers. Despite a minimal initial investment, the program has already demonstrated significant logistical improvements for maintenance training operations.

The core innovation lies in printing spare training parts critical for onboarding new maintenance workers to the MQ-9 Reaper’s maintenance, repair, and overhaul (MRO) protocol. What makes this approach remarkable is its economic impact. Remington Young, an MQ-9 AFETS airframe propulsion specialist, noted the dramatic cost reduction: “It’s a funny story, given that my first 3D printer was from my wife for Christmas in 2016. Now we are printing military training equipment. This technology empowers our Airmen with practical skills, saving lives and dramatically reducing costs. A part that once cost $10,000 can now be rapidly 3D-printed for just $15.”

Eric Pavelka, a senior avionics equipment specialist, explained the program’s inception. “There are a lot of rules when it comes to money and what we’re actually able to purchase,” he said. “But we all came to the consensus of a legitimate need for printers because we could see the added benefits that it would provide for all of our training.”

The application of 3D printing in military training represents more than just a cost-saving measure. It serves multiple functions: enhancing maintenance worker training, familiarizing personnel with advanced manufacturing processes, and enabling more active financial management of Department of Defense MRO operations.

An interesting footnote to the program involves the printers themselves. The equipment appears to be manufactured by Bambu Lab, which could potentially raise eyebrows given ongoing concerns about Chinese products in strategic supply chains. The incoming administration’s potential “Made in USA” mandate for government equipment purchases adds another layer of complexity to the initiative.

The program draws parallels with previous military additive manufacturing efforts, such as the Maine Air National Guard’s use of Essentium printers to produce training replicas. It highlights a growing trend of military organizations leveraging emerging technologies to address practical training challenges.

While the application might seem niche, it represents a significant breakthrough in military training methodologies. By transforming how maintenance personnel acquire and practice critical skills, the 432nd Wing is demonstrating the potential of additive manufacturing to revolutionize military training approaches.

As the DoD continues to explore innovative solutions, the Creech AFB 3D printing program stands as a compelling example of how technology can simultaneously reduce costs, improve training, and enhance operational readiness. It is a testament to military ingenuity that personnel have devised such creative solutions to long-standing logistical problems.

Images credit: US Air Force/Renee Blundon

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Alexa Sipes

Alexa Sipes is a U.S. tech journalist with 5 years of experience, now writing for 360TechInsights. She covers emerging technologies and industry trends across North America, Europe, and Asia. Sipes’ concise reporting offers readers valuable insights into the latest tech news, innovations and the companies behind them.

Feel free to reach out to me at AlexaSipes@360techinsights.com.