NAVAIR completes first flight with safety critical 3D printed parts

The US Naval Air Systems Command (NAVAIR) has successfully completed the first flight demonstration of a flight critical aircraft component built using additive manufacturing.

The MV-22B Osprey completed a test flight fitted with a titanium, 3D printed link and fitting assembly for the engine nacelle.  According to NAVAIR, the assembly is one of four that secure a V-22’s engine nacelle to the primary wing structure and will remain on the aircraft for continued evaluation. 

“The flight went great. I never would have known that we had anything different on-board,” said MV-22 Project Officer Maj. Travis Stephenson, who piloted the flight.

The metal link and fitting assembly for the flight were printed at Naval Air Warfare Center Aircraft Division in Lakehurst, New Jersey.  Prior to the flight, multiple V-22 components built by Lakehurst and Penn State Applied Research Laboratory were tested at Patuxent River for validation.