CHERRY POINT, N.C. –
Fleet Readiness Center East (FRCE) has entered a new phase of metal additive manufacturing (AM) with the delivery of its first flight-certified, 3D-printed aluminum aircraft parts, an advancement poised to cut downtime and strengthen flight line readiness across multiple platforms.
A partnership between the Naval Air Systems Command (NAVAIR) AM Team and Fleet Support Teams has enabled FRCE’s Advanced Technology and Innovation Team to develop its processes and earn certification to produce non-flight-critical metal components. Using high-powered lasers to weld thin layers of aluminum powder into solid objects, the depot has now manufactured and delivered three flight-worthy parts: an AH-1Z Viper weapons pylon fitting, a V-22 Osprey main landing gear repair fitting and a C-130 Hercules blanking plate.
The integration of metal AM marks a strategic shift in how the command supports fleet readiness. On-demand metal printing offers a more efficient, localized alternative to traditional supply chains, reducing maintenance lead times, easing procurement bottlenecks and keeping aircraft mission ready. It also aligns with FRCE’s broader modernization push to expand AM across depot operations.
FRCE reached a second milestone along the way: successfully completing its rigorous, formal capability demonstration in under six months. This validation confirmed that FRCE-produced metal AM parts meet the same safety and quality standards as traditionally manufactured components.
“We were challenged to complete the qualification, production and certification processes for these parts in six months, and we not only met but exceeded that standard,” said the Advanced Technology and Innovation Team lead. “This is the fastest this sort of thing has ever been done within Naval Air Systems Command, and it shows that we are competitive with industry standards.”
The depot’s first flight-certified metal AM aircraft part, the AH-1Z pylon fitting, is a small but important attachment point for the aircraft’s weapon pylons. FRCE delivered the pylon fitting to the H-1 Fleet Support Team in early 2025, followed by the V-22 landing gear repair fitting and the C-130 blanking plate later that year. FRCE has also used the technology to produce specialized tooling and support equipment for the depot’s maintainers, improving efficiency on the shop floor.
Metal AM is also proving its value in urgent fleet scenarios when a time-saving solution is vital to readiness. “If there’s a fight and the fleet needs these parts tomorrow, they won’t have time to wait for those parts through traditional supply chains,” said the FRCE AM Team lead. “The fleet was having a hard time getting their hands on repair fittings for the V-22 main landing gear—it’s basically a doorstop for the landing gear door when it comes up. They turned to additive manufacturing and asked us if it was something we could make, so we took on that part, and a few others, as part of our capability demonstration. The goal is to give the fleet what they need, when they need it, and we did just that.”
Next, FRCE plans to expand into stainless steel printing, enabling production of stronger, more durable flight-critical parts and support equipment for the fleet to further increase flight line readiness.
