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The US Air Force installs 3D printed draft reducers for the C-17, saving more than $ 14 million in fuel costs each year

New “Advanced Compensation” Technology Improves Precision in Metal 3D Printing

Introduction:The plane reduces the drag during the flight, which not only reduces fuel consumption, but also increases the scope and increases the flight speed. Consequently, improving aerodynamic efficiency has always been an important objective of optimizing aviation. Today, additive manufacturing technology (3D printing) has shown new possibilities in this area.


On January 8, 2025, according to the resource library, the USA Air Force (USAF) Air Force Energy Office and Air Mobility Command Command applied the C-17 Globemaster III Transport Aircraft. .
The C-17 is an important strategic transport aircraft for the American army. To further improve its combat capacities and optimize energy efficiency, the US Air Force constantly improves the C-17 fleet, and 3D printed microblades are an important part of this optimization measure.
3D printing of micro blades: effective reduction in resistance
So what exactly are micro-gears printed in 3D? These blades measure approximately 4 x 16 inches (about 10 x 40 cm) in shape and resemble thin blades. During installation, the technicians used the high-resistance adhesive to secure approximately 12 micro blades on the external rear of the body C-17. The project was promoted by the Air Force Research Laboratory (AFRL), private companies and the Air Force life cycle management center (AFLCMC), and has been tested for a long time.


Preliminary test results show that technology has significant results. Compared to the not modified C-17, resistance to the flight of the plane equipped with micro blades printed in 3D has been reduced by 1%. Although the drop seems to be low, the real advantages are considerable: to improve the efficiency of the use of fuel, prolong the flight beach and reduce air resistance in the cargo door area.
According to Air Force calculations, technology can allow the American army of more than $ 14 million in fuel costs each year. Given that fuel consumption is closely linked to logistics supply, the reduction of resistance reduces not only operating costs, but also improves the level of combat preparation of the American army and combat capacities .
Future plan: expand the scope of the application
Currently, six C-17 transport aircraft have completed the modification of microblade and entered the logistics services evaluation stage (LSA). LSA is the final test before the full deployment, the evaluation cycle should be 6 months and will be officially launched after the end of the modification of the two additional planes. .


It should be noted that the prospects for applying 3D microblade technology are not limited to the US Air Force. Due to its advantages in reducing fuel consumption and improving combat capacities, the Canadian and British air forces have shown strong interest in this technology and plan to be tested and applied in their own C- 17.
Finally, the successful application of micro-blade printed in 3D marks an important step forward in optimizing the performance of traditional aircraft. This low -cost and high -efficiency technology should be widely used in other military and civil aircraft in the future, and has a deep impact on world air transport.

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