US Navy Fleet Readiness Center East Delivers First Metal 3D-Printed Parts

This article is based on an official press release from the United States Navy.

The United States Navy’s Fleet Readiness Center East (FRCE) has officially entered a new era of aircraft sustainment, delivering its first flight-certified metal 3D-printed parts to the fleet. According to an official press release, this milestone is expected to significantly reduce aircraft downtime and improve flight line readiness for critical Military-Aircraft assets.

The achievement stems from a collaboration between the FRCE’s Advanced Technology and Innovation Team, the Naval Air Systems Command (NAVAIR) Additive Manufacturing Team, and various Fleet Support Teams. By leveraging metal additive manufacturing, the depot has successfully developed processes and obtained certifications to produce non-flight-critical aircraft components on demand.

We recognize this development as a major step forward in military logistics. By producing parts locally and rapidly, the Navy can bypass traditional supply chain bottlenecks, ensuring that aircraft remain operational when they are needed most.

First Flight-Worthy Deliveries

Unlike traditional 3D printing that uses plastic filament, the FRCE’s metal additive manufacturing process utilizes high-powered lasers to weld thin layers of aluminum powder into solid objects. The official release notes that since establishing this capability, the facility has manufactured and delivered three specific flight-worthy parts to the fleet.

The first of these components was a weapons pylon fitting for the AH-1Z Viper, which was delivered to the H-1 Fleet Support Team in early 2025. Later that year, the depot supplied a repair fitting for the main landing gear of the V-22 Osprey, as well as a blanking plate for the C-130 Hercules.

Rapid Certification and Production

Beyond the physical deliveries, the FRCE achieved a significant administrative and operational milestone by completing a rigorous capability demonstration in under six months. This rapid turnaround serves as formal validation that the 3D-printed metal parts meet the same stringent safety and quality requirements as traditionally manufactured components.

“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,” stated the FRCE’s Advanced Technology and Innovation Team lead in the press release. “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.”

Overcoming Supply-Chain Hurdles

The integration of metal additive manufacturing represents a strategic shift in how the military supports its warfighters. By producing parts in-house, the Navy can provide a time-saving solution for replacing worn or damaged components that are often difficult to source through traditional procurement channels.

For example, the V-22 Osprey fleet had been experiencing difficulties obtaining repair fittings for its main landing gear. According to the Navy’s statement, the fleet turned to the additive manufacturing team to solve this shortage, resulting in the successful production of the needed parts during the capability demonstration phase.

Future Expansion into Stainless Steel

Looking ahead, the FRCE plans to expand its additive manufacturing capabilities beyond aluminum. The press release indicates that the facility will soon begin working with stainless steel, a material that offers greater strength and durability. This expansion will enable the depot to produce a wider array of flight-critical parts and support equipment.

In addition to aircraft components, the FRCE is already utilizing its 3D printing equipment to create specialized tooling and support parts for its own maintainers, streamlining the repair process across the board.

AirPro News analysis

We view the FRCE’s rapid adoption of metal additive manufacturing as a critical indicator of broader trends in aerospace and defense logistics. The ability to certify and produce metal parts in under six months demonstrates a significant maturation of 3D printing technologies within highly regulated environments. As the FRCE, North-America‘s largest maintenance, repair, and overhaul provider with over 4,000 workers and $865 million in annual revenue, expands into stainless steel, we anticipate a cascading effect where localized, on-demand manufacturing becomes the standard rather than the exception for military sustainment.

Frequently Asked Questions

What is metal additive manufacturing?

Metal additive manufacturing is a 3D printing process that uses high-powered lasers to weld thin layers of metal powder (such as aluminum or stainless steel) into a solid, functional object.

Which aircraft received the first 3D-printed parts from FRCE?

According to the Navy’s press release, the first parts were delivered for the AH-1Z Viper, the V-22 Osprey, and the C-130 Hercules.

How long did the certification process take?

The FRCE completed the rigorous capability demonstration and Certification process in under six months, marking the fastest timeline for this type of achievement within the Naval Air Systems Command.

Sources

• United States Navy