First FRCE certified metal AM parts delivered to US fleet
A collaboration between the US Naval Air Systems Command (NAVAIR) Additive Manufacturing Team and Fleet Support Teams has enabled the Advanced Technology and Innovation Team at Fleet Readiness Center East (FRCE), Havelock, North Carolina, to achieve certification to produce its first non-flight-critical aircraft parts using metal Additive Manufacturing.
FRCE has now delivered its first flight-certified metal additively manufactured parts to the fleet, reportedly reducing aircraft downtime and supporting improved flight line readiness.
Since establishing a capability to produce aluminium components with Laser Beam Powder Bed Fusion (PBF-LB), FRCE has manufactured and delivered three flight-certified parts: a weapons pylon fitting for the AH-1Z Viper, a repair fitting for the main landing gear of the V-22 Osprey, and a blanking plate for the C-130 Hercules.
According to the depot, the introduction of metal Additive Manufacturing represents a change in the command’s support strategy, enabling more localised, on-demand production of replacement parts. This approach is intended to reduce maintenance lead times and improve aircraft availability.
“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,” the team lead said. “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. This entire process has been a team effort between FRC East, our headquarters, the site in Lakehurst, and the Fleet Support Teams, working together to ensure these parts are ready and reliable for our troops.”
This process demonstration is said to validate the depot’s metal AM processes and confirms that parts produced at the facility meet the same safety and quality requirements as conventionally manufactured components, according to NAVAIR. The achievement was described by the FRCE Advanced Technology and Innovation Team as the result of collaboration across multiple NAVAIR teams.
The pylon fitting was the first flight-certified metal additively manufactured aircraft part produced by the depot. It was delivered to the H-1 Fleet Support Team in early 2025, followed by the landing gear repair fitting for the V-22 Fleet Support Team and the blanking plate for the C-130 Fleet Support Team later in the year.
In addition to flight-certified components, FRCE has used its metal Additive Manufacturing machines to produce tooling and support parts for maintenance operations, supporting more efficient repair workflows.
Metal AM offers a route to replace worn or damaged components that may be difficult to source through traditional supply chains. Producing parts in-house and on demand is expected to reduce aircraft downtime and improve operational 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,” the team lead said. “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.”
FRCE plans to expand its metal AM capability to include stainless steel, enabling the production of a wider range of components and support equipment for the fleet.
