Defense & Military
Settlement Reached in 2021 Navy Helicopter Crash Lawsuit
Families of sailors killed in 2021 Navy helicopter crash settle lawsuit over design defects and maintenance issues with Sikorsky Aircraft.
Settlement Reached in Lawsuit Regarding Fatal 2021 Navy Helicopter Crash
On November 24, 2025, a significant legal development occurred regarding the tragic 2021 crash of a U.S. Navy MH-60S Sea Hawk helicopter. The families of three sailors who lost their lives in the incident reached a confidential settlement with Sikorsky Aircraft Corp., a Lockheed Martin company. This agreement resolves a lawsuit filed in the U.S. District Court for the Southern District of California, bringing a conclusion to the legal battle over allegations of design defects and negligence.
The lawsuit, originally filed in August 2023, centered on the mechanical failure that led to the loss of the aircraft, known by its call sign “Loosefoot 616.” The plaintiffs represented the estates of Petty Officer 2nd Class James Buriak, Petty Officer 2nd Class Sarah Burns, and Petty Officer 3rd Class Bailey Tucker. These sailors, along with Lt. Bradley Foster and Lt. Paul Fridley, perished when their helicopter experienced catastrophic vibrations and fell from the flight deck of the USS Abraham Lincoln into the Pacific Ocean.
This settlement marks the end of the civil litigation against the helicopter manufacturer for these specific families. While the financial terms remain undisclosed, the case has highlighted critical issues regarding military aircraft maintenance protocols, design safety, and the legal frameworks governing accidents at sea. We examine the details of the allegations, the technical findings of the Navy’s investigation, and the broader safety implications for the fleet.
Allegations of Design Flaws and Negligence
The core of the plaintiffs’ case against Sikorsky Aircraft rested on the assertion that the MH-60S helicopter contained a design flaw within its hydraulic hose assembly. According to court documents, the families argued that the hydraulic damper hoses were positioned too close to the main rotor attachment point. This proximity, they alleged, made the components highly susceptible to damage during routine maintenance operations.
Legal representatives for the families, specifically attorneys from Pilot Law, P.C., contended that the manufacturer failed to warn operators of this vulnerability. The lawsuit claimed that the design allowed for the steel braids inside the hose to be flattened or crushed without leaving visible external signs of damage. Consequently, maintenance crews could not detect the structural compromise through standard visual inspections, creating a latent hazard that could lead to catastrophic failure during flight operations.
The complaint was filed under the Death on the High Seas Act (DOHSA), a federal statute from 1920 that governs civil recovery for deaths occurring beyond three nautical miles from the shore of the United States. The plaintiffs sought to hold the manufacturer accountable for what they described as a preventable defect that directly contributed to the fatal sequence of events on August 31, 2021.
The lawsuit argued that the design allowed damage to occur easily and that the steel braids inside the hose could be flattened without being visible during visual inspections.
Investigation Findings and Technical Cause
A command investigation conducted by the U.S. Navy, released in 2022, largely corroborated the technical theories presented by the plaintiffs. The investigation identified the root cause of the crash as the in-flight failure of a main rotor damper hose. This failure resulted in a total loss of damping for the main rotor system. Upon landing on the flight deck, the aircraft immediately entered a state of violent “ground resonance”, severe lateral vibrations that caused the rotor blades to strike the deck and the aircraft to roll over into the sea.
The Navy’s inquiry pinpointed the likely mechanism of damage to the use of a specific maintenance tool known as a “spindle pry bar.” Investigators determined that if this tool was used incorrectly or without sufficient clearance, it could inadvertently kink or crush the damper hose. Because the internal damage was not visible to the naked eye, the compromised hose remained in service until it failed under the stress of operations.
Following these findings, the Navy took immediate remedial action to prevent a recurrence. In late 2021, an “Interim Support Equipment Change” was issued, directing the modification of the spindle pry bar. A “hard stop” was added to the tool to physically prevent it from contacting the damper hose. Furthermore, a “Rapid Action Change” ordered the fleet-wide inspection and replacement of damper hoses. A 2022 memo signed by Vice Admiral Steve Koehler formally acknowledged that these modifications were necessary to prevent damage, validating the concerns regarding the interface between the maintenance tools and the aircraft’s design.
Legal Context and Future Implications
The resolution of this case draws attention to the legal complexities facing military families seeking redress for accidents at sea. Because the crash occurred approximately 60 nautical miles off the coast of San Diego, the case fell under the jurisdiction of the Death on the High Seas Act (DOHSA). Historically, DOHSA limits recovery strictly to “pecuniary loss,” which refers to the financial support the deceased would have provided to their dependents. It generally excludes damages for the families’ pain and suffering or the pre-death pain and suffering of the victims.
This legal limitation has been a subject of legislative debate. The “Fairness for Fallen Sailors Act,” introduced in the 2025-2026 Congress, aims to amend DOHSA to allow for non-pecuniary damages in non-commercial aviation accidents. While the bill had passed the House as of April 2025, it was still navigating the Senate at the time of this settlement. The existence of such legislation highlights the hurdles families face in securing what they view as comprehensive justice under current maritime law.
With the settlement now finalized, the civil litigation against Sikorsky regarding the “Loosefoot 616” crash is concluded for these plaintiffs. The case serves as a somber reminder of the critical importance of integrating human factors into aircraft design and the necessity of rigorous maintenance protocols. The modifications implemented by the Navy following the crash remain in effect, serving to protect current and future crews operating the MH-60S Sea Hawk.
FAQ
Question: Who were the plaintiffs in the lawsuit against Sikorsky?
Answer: The lawsuit was filed by the families of Petty Officer 2nd Class James Buriak, Petty Officer 2nd Class Sarah Burns, and Petty Officer 3rd Class Bailey Tucker.
Question: What was the technical cause of the crash?
Answer: A U.S. Navy investigation determined the crash was caused by the failure of a main rotor damper hose, likely damaged during maintenance by a spindle pry bar, which led to severe vibrations upon landing.
Question: What is the Death on the High Seas Act (DOHSA)?
Answer: DOHSA is a 1920 federal law that governs wrongful death claims occurring more than three nautical miles from U.S. shores, typically limiting recovery to financial (pecuniary) losses rather than pain and suffering.
Sources
Photo Credit: US Navy MC Seaman Marco Villasana
Defense & Military
Pratt Whitney Completes 3D-Printed TJ150 Turbojet Demo Test
Pratt & Whitney validates additive manufacturing for the TJ150, consolidating 50+ hot section parts into 3D-printed components.
Pratt & Whitney has successfully completed demonstration testing of an additively manufactured TJ150 turbojet engine, a process that consolidated more than 50 individual hot section components into a small number of 3D-printed parts.
The RTX Corporation subsidiary announced the milestone on July 20, 2026, during the Farnborough International Airshow in London. The test results validate the manufacturer’s strategy to use additive manufacturing to simplify design and accelerate production for expendable military propulsion systems.
Consolidating hot section components
According to the press release, nearly 60 percent of the TJ150 engine’s volume was produced using additive manufacturing. This volume includes major static and rotating hardware. By utilizing 3D printing technologies, engineers reduced the complexity of the engine’s hot section and replaced over 50 traditional parts with a handful of consolidated components.
The TJ150 is a 150-pound thrust class turbojet designed for single-use applications.
“For expendable engines like the TJ150, where missions can last minutes or hours, simplifying the design and scaling production quickly is essential to meeting rising demand,” said Jill Albertelli, President of Military Engines at Pratt & Whitney.
Integration with cruise missiles and decoys
The successful demonstration of the 3D-printed TJ150 follows recent contract awards and integration announcements for the engine platform. On March 10, 2026, Pratt & Whitney secured a follow-on contract from Leidos Dynetics to supply TJ150 engines for the AGM-190A small cruise missile.
In a separate announcement on July 15, 2026, Raytheon confirmed plans to prioritize the TJ150 engine for the initial production of the Miniature Air-Launched Decoy (MALD). Raytheon noted that utilizing the existing engine platform keeps restart timelines short while the company explores additively manufactured engines for longer-term opportunities.
Expanding additive manufacturing applications
Pratt & Whitney plans to apply the manufacturing techniques validated during the TJ150 demonstration to other propulsion programs. Albertelli stated that additive manufacturing helps the company move designs from concept to capability faster. She confirmed that the manufacturer is leveraging the TJ150 learnings to benefit other systems, including the Pratt & Whitney Valox engine family.
AirPro News analysis
The successful test of a heavily 3D-printed TJ150 highlights a critical shift in defense aerospace manufacturing. As military operators demand higher volumes of autonomous systems, decoys, and tactical missiles, traditional supply chains for small turbine engines face significant bottlenecks. Casting and machining conventional hot-section components requires extensive tooling and long lead times. By consolidating dozens of parts into a few additively manufactured pieces, we see manufacturers directly addressing the need for rapid scalability.
Expendable engines operate for very short durations, meaning they do not require the same long-term durability as commercial or manned military turbofans. This specific operational profile makes them ideal candidates for additive manufacturing, allowing producers to prioritize production speed and cost reduction over thousands of hours of time-on-wing reliability.
Photo Credit: RTX
Defense & Military
GE Aerospace and Magellan Sign F414 MRO MOU for Canada
GE Aerospace and Magellan Aerospace signed an MOU at Farnborough to establish a Canadian F414 engine MRO center if Canada selects the Gripen E.
GE Aerospace and Magellan Aerospace Corporation signed a Memorandum of Understanding (MOU) on July 22, 2026, at the Farnborough International Airshow to establish a Canadian MRO center for the F414-GE-39E engine. The agreement is entirely contingent on the Government of Canada selecting the Saab JAS 39 Gripen E for its future fighter fleet.
Announced in a GE Aerospace press release, the proposed MRO work would take place at Magellan’s facility in Mississauga, Ontario. The partnership aims to position Magellan as Canada’s domestic center of excellence for F414 engine sustainment, guaranteeing sovereign support capabilities for the Royal Canadian Air Force (RCAF) if the Gripen E is acquired.
Industrial offsets and the Gripen E campaign
The MOU represents a calculated component of a broader industrial offset campaign by Saab AB and its suppliers to secure a portion of Canada’s fighter procurement contract. The Canadian government is currently reviewing its fighter jet strategy. While Ottawa previously committed to purchasing a fleet of 88 Lockheed Martin F-35A Lightning II Military-Aircraft, the government is evaluating a potential mixed fleet that could include domestically built Gripen E fighters.
To strengthen the Gripen’s bid, Saab has been securing agreements with Canadian aerospace firms to promise domestic job creation and technology transfer. This engine sustainment agreement follows a similar MOU signed on July 17, 2026, between Saab and Canadian aviation training firm CAE Inc. to cooperate on advanced fighter pilot Training.
Engine sustainment and domestic capabilities
The F414 engine family has accumulated more than 5 million flight hours globally. The new agreement builds on a 60-year working relationship between GE Aerospace and Magellan Aerospace Corporation.
Paul Ferraro, Vice President of Defense Engines & Services at GE Aerospace, stated that the agreement spans both military and commercial engines and will ensure the RCAF has in-country access to sustainment services to maintain F414 readiness.
Haydn Martin, Vice President of Business Development, Marketing, and Contracts at Magellan Aerospace Corporation, emphasized the operational benefits of the proposed partnership.
“Should the Saab JAS 39 Gripen E aircraft be selected, Magellan Aerospace will be ready to provide world-class engine maintenance, repair and overhaul services that enhance operational readiness for the Royal Canadian Air Force while maintaining highly skilled Canadian jobs, developing advanced technical expertise, and strengthening Canada’s long-term defence industrial capacity,” Martin said.
AirPro News analysis
We view this MOU as a clear signal that the competition for Canada’s fighter fleet remains highly active despite the initial F-35A selection. By lining up domestic heavyweights like Magellan and CAE, Saab is directly addressing Ottawa’s stringent Industrial and Technological Benefits (ITB) policy requirements. If the Government of Canada opts for a mixed fleet, establishing sovereign MRO capabilities for the F414 engine will be a critical factor in mitigating supply chain risks and ensuring RCAF operational independence. Until a formal procurement decision is finalized, these agreements remain strategic positioning rather than guaranteed Contracts.
Sources: GE Aerospace
Photo Credit: GE Aerospace
Defense & Military
CBP AMO Orders 10 Airbus H125 Helicopters for Fleet Expansion
CBP Air and Marine Operations contracts for 10 Airbus H125 helicopters, expanding a 30-year fleet of over 100 rotary-wing aircraft.
U.S. Customs and Border Protection Air and Marine Operations (CBP AMO) has finalized a contract to acquire 10 additional Airbus H125 helicopters, expanding a fleet modernization effort that relies heavily on the single-engine platform for border security and law enforcement missions.
In a press release issued on July 7, 2026, Airbus confirmed the agreement, which reinforces a three-decade relationship between the federal agency and the aerospace manufacturer. The new helicopters will be assembled at the Airbus Helicopters production facility in Columbus, Mississippi.
Expanding the airborne law enforcement fleet
The latest acquisition builds upon a previous order placed in August 2020, when CBP AMO contracted for 16 H125 helicopters to upgrade its aging rotary-wing assets. The agency currently operates a total fleet of more than 240 aircraft, which includes over 100 helicopters from the Airbus H120 and H125 families delivered over the past 30 years.
The H125, formerly known as the Eurocopter AS350, is utilized by CBP AMO for a variety of demanding flight profiles, including border surveillance, suspect pursuit, and general public safety operations across the United States.
Bart Reijnen, Head of the North America Region for Airbus Helicopters, stated that the expansion “underscores the long-standing collaboration” between the manufacturer and the federal agency. He added that the selection highlights the trust placed in the H125 to execute critical public safety missions under demanding conditions, with Airbus committing to provide comprehensive services to maintain mission readiness.
Virtual reality integration for pilot training
As CBP AMO increases its H125 inventory, the agency is simultaneously overhauling how it trains the personnel who fly them. In November 2025, CBP became the first federal law enforcement agency and the first branch of the U.S. Department of Homeland Security (DHS) to integrate virtual reality into its aerial training program.
According to reporting by FLYING Magazine, the agency awarded a contract to adopt an FAA-qualified Airbus H125 virtual reality flight simulator developed by Loft Dynamics. The simulator is being installed at the CBP AMO training center in Oklahoma City, where it will be used to train the agency’s roster of more than 600 pilots.
AirPro News analysis
We view CBP AMO’s continued investment in the H125 platform as a clear indicator of the agency’s preference for fleet commonality. Operating a standardized fleet of over 100 H125-family helicopters significantly reduces maintenance overhead, streamlines supply chains, and simplifies pilot transition training. Furthermore, Airbus’s strategy of assembling these aircraft in Columbus, Mississippi, likely plays a crucial role in navigating federal procurement requirements, ensuring that the European manufacturer remains highly competitive for U.S. government contracts. The parallel investment in Loft Dynamics’ VR simulators suggests the agency is preparing for a sustained, long-term operational lifespan for the H125 fleet.
Sources: Airbus
Photo Credit: Airbus
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