3D printed parts for the C-5M deliver new capabilities

Maintainers from the 60th Maintenance Squadron and 349th Aircraft Maintenance Squadron, along with Engineering and Engineering Support contractors from the C-5 System Program Office out of Robins AFB, Georgia, began maintenance last month to modify an aerodynamic fairing for a C-5M Super Galaxy by incorporating printed 3D parts.

airmen working on an aircraft's wing
3D printed parts for the C-5M deliver new capabilities
Airman from the 60th Maintenance Squadron and 349th Maintenance Squadron, prepare the wing surface of a C-5M Super Galaxy for maintenance at Travis Air Force Base, California, Jan. 31, 2023. Maintainers from the 60 MXS and 349 MXS modified an aerodynamic fairing over a wing splice of a C-5M Super Galaxy incorporating newly printed 3D parts known as blocks and wedges. (U.S. Air Force photo by Lan Kim)
The printed blocks and wedges, supplied by the USAF Rapid Sustainment Office, provide internal support to the C-5 hump panel covering a wing splice, as described by Clay Elliott, a C-5 structural engineering subject matter expert with the C-5 SPO.
To get the aircraft fixed as soon as possible, Elliott proposed to integrate the 3D printed parts made from Antero 800NA, a new thermoplastic material, into the aircraft repair.
airmen working together in preparing an aircraft part
3D printed parts for the C-5M deliver new capabilities
U.S. Air Force Staff Sgt. Timothy Jones, 60th Maintenance Squadron aircraft structural maintenance supervisor, left, monitors Senior Airman Andrew Serrato, 349th Aircraft Maintenance Squadron aircraft structural maintenance journeyman, as he prepares a fastener strap at Travis Air Force Base, California, Jan. 31, 2023. The strap was fitted with newly 3D printed blocks meant for maintenance on a C-5M Super Galaxy. (U.S. Air Force photo by Lan Kim)

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After a team of maintainers fixed the panel at Charleston, the aircraft was flown back to Travis for further maintenance. The process involved completely removing the legacy parts from the plane and re-bonding the new 3D printed blocks and wedges to the aircraft and re-installing the panels.