A collaboration between U.S. Marine Corps and Air Force maintainers returned a grounded F-15 Eagle to service in less than 12 hours using additive manufacturing, avoiding what would have been a three- to four-month repair delay.
The aircraft had been grounded at Kadena Air Base, Okinawa, after maintainers discovered a crack in the right-hand cockpit cooling duct during a post-flight inspection. The part was unavailable through traditional supply channels, and initial assessments indicated the aircraft would remain out of service for months.
Air Force maintainers from the 18th Maintenance Group initially attempted to repair the component using conventional methods, intending to preserve as much of the original material as possible. After consulting with a depot liaison engineer, they turned to additive manufacturing to print a replacement part instead.
The 18 MXG team printed two prototypes but encountered technical difficulties before achieving a part that met specifications. Knowing that Marine Aircraft Logistics Squadron 36 had the same equipment, they requested assistance. MALS-36 produced two working prototypes that were delivered and fit-checked in under 12 hours.
The Marine maintainers also provided an unexpected benefit. After reviewing the Air Force’s technical data package, they developed an improved design that reduced the part’s print time by two hours while maintaining structural integrity.
“We were skeptical of the first design provided by [the MALS] due to the significant shorter print time compared to our first prints,” said U.S. Air Force Capt. Diego Carrillo, a depot liaison engineer. “Our techs learned that the duct’s orientation affects the necessity for the support structures, which allowed the Marines to reduce the duct’s print time without compromising its structural integrity.”
The repair represents what Theodore Gronda, NAVAIR Additive Manufacturing Program Manager, called a demonstration of joint service cooperation. “Here was a situation where a multi-million dollar aircraft was going to be sidelined for months due to the lack of a part in the supply system,” Gronda said. “This was truly a glowing example of a ‘One Team, One Fight’ effort.”
The improved design developed through the collaboration has now been incorporated into Air Force additive manufacturing technical publications and will be used for similar repairs across the F-15 community.
According to Carrillo, additive manufacturing serves as a force multiplier in applications where parts are non-procurable or have long lead times. “This capability is critical when items are not available from the supply chain or cannot be purchased from industry when needed,” he said.
The NAVAIR Additive Manufacturing team supports Navy and Marine Corps maintainers with training, engineering support, and technical data to increase readiness in forward-deployed locations where traditional logistics face challenges.
Carrillo said the collaboration demonstrates broader benefits beyond a single repair. “Cooperative and joint exercises with sister services and other stakeholders can help cross-pollinate ideas and methodologies, strengthen partnerships and increase force effectiveness,” he said.
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