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RAF Installs First In-House 3d Printed Part on Typhoon Jet

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Business Honor - RAF Fits First 3D Printed Part on Typhoon Jet

Business Honor
13 August, 2025

The RAF has successfully installed its first in-house 3D printed part on a Typhoon jet, enhancing aircraft maintenance efficiency.

In a historic move for military flight, the Royal Air Force (RAF) has fitted its first in-house produced 3D printed part to an in-service Typhoon combat aircraft. The component, a pylon assembly temporary fix, was designed and created in-house at the Hilda B. Hewitt Centre for innovation, marking the increasing place of additive manufacturing in defense maintenance and repair.

No 71 Inspection & Repair Squadron engineers employed advanced 3D scanning and printing methods to fabricate the component—a repair piece for an Anti-Yaw Spigot—after damage was discovered on Typhoon ZK309. As a permanent replacement was being developed by the original equipment manufacturer, 71 Squadron quickly manufactured a temporary one to maintain the jet in flying condition. The component was then successfully fitted by 29 Squadron technicians at RAF Coningsby.

“This isn’t a permanent fix, but it shows where we’re heading,” said Squadron Leader John Mercer, Senior Engineering Officer at 29 Squadron. “Being able to print our own temporary components means getting jets back in the air faster when waiting for spare parts would cause delays.” The RAF's transition to in-house 3D printing dramatically cuts aircraft downtime and demonstrates the agility and quickness of additive manufacturing. No. 71 Squadron, which is within the RAF Support Force, is the expert in non-conventional repairs and structural repairs for UK military aircraft.

Officer Commanding Air Wing Engineering Wing Commander Gemma Lonsdale highlighted the broader potential: "This technology has huge potential to keep our aircraft in the air faster than ever before." With this successful test, the RAF aims to extend the application of 3D printing throughout its fleet—providing cost benefits, operational resilience, and improved self-sufficiency in future military aviation support.