After years of testing and refinement, the U.S. Air Force’s microvane program is nearing full implementation across it’s C-17 fleet. These small, strategically placed devices are set to reduce aerodynamic drag and increase fuel efficiency by redirecting airflow around the aircraft’s fuselage, proving that even the most mature aircraft designs can be enhanced.
Air Force Operational Energy and Air Mobility Command are now in the final stages of evaluating the microvane technology. The microvanes themselves are deceptively simple: small, 3D-printed devices, measuring approximately 4 x 16 inches, and shaped like a thin blade. These are attached to the rear of the C-17’s fuselage using strong adhesive bonding. A dozen of these devices are placed strategically to redirect airflow, reduce drag, and cut fuel consumption by approximately one percent. This seemingly small reduction is expected to have a substantial impact over the entire fleet.
The financial implications of this technology are striking. With the projected savings of over $14 million annually, the investment in microvanes is expected to pay for itself in just seven months. This represents not only a cost-saving measure but a significant stride in increasing operational capabilities. The enhanced fuel efficiency means an extended mission range and improved support to the joint force in high-demand operations. The technology has garnered significant interest from partner nations, including Canada and the United Kingdom, who are also considering adopting the modification for their own C-17 fleets.
Currently, six aircraft are undergoing modification for the Logistics Service Assessment (LSA). This is the final step before the microvanes are introduced to the entire U.S. Air Force C-17 fleet.
This initiative did not appear out of the blue. Its origins can be traced back to the C-17 Drag Reduction Program, which was launched at Edwards Air Force Base in 2016. This program sought to gather data on how various modifications to the C-17 would impact airflow. The initial phase of testing involved Vortex Control Technologies Finlets (TM), which are small structures attached to the aft part of the fuselage. These tests also incorporated microvanes and fairings, as the Air Force explored which modifications would be most effective. The microvanes, described as small, blade-like devices, showed promise from the beginning. The goal was clear: to reduce fuel consumption without compromising the C-17’s mission capabilities.
In 2018, the AFRL continued its work in collaboration with Dover Air Force Base and private companies to refine the microvane technology. The nylon microvanes were enhanced with 3D-printed glass beads. At Dover AFB, twelve microvanes were installed on a C-17 using a Mylar template. The microvanes work by cleaning up the airflow, reducing drag through small vortices that delay separation and smooth the flow. At the time, it was estimated that if all 222 U.S. Air Force C-17s had microvanes installed, it would save between five and seven million dollars annually.
Moreover, flight testing at Edwards AFB validated the 1% drag reduction. It also confirmed that there was no negative impact on critical air drop mission capability.
More broadly, the microvane program is part of a larger Air Force effort, starting in 2022, to introduce aerodynamic technologies across various mobility aircraft including the KC-135 Stratotanker and C-130 Hercules. This involves collaborations with commercial vendors to improve airflow and reduce maintenance issues. The Air Force is also pursuing broader optimization initiatives, encompassing everything from drag reduction efforts to engine sustainment and mission planning software upgrades. These programs are part of the Air Force’s push to “Accelerate Change” by increasing readiness and addressing logistics challenges, in line with the Department of Defense’s climate mitigation goals.
The benefits of the microvane program are substantial. It is expected to yield millions of dollars in fuel cost savings, along with increased mission range, improved mobility, and enhanced support to the joint force. Most importantly, the program strengthens the Department’s ability to sustain operations in contested environments.
The impending implementation of the microvane technology highlights how relatively simple modifications to existing aircraft can yield significant benefits. As the final stages of the evaluation conclude, the U.S. Air Force is looking ahead to the expected fleet-wide implementation, anticipating its positive impact on future operations.
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