Fast Repair: U.S. Navy repairs fighter jets with 3D-printed patches

Fast Repair: U.S. Navy repairs fighter jets with 3D-printed patches highlights a shift toward faster maintenance for composite aircraft parts. The U.S. Navy’s Naval Air Warfare Center Aircraft Division (NAVCAD) and Fleet Readiness Center Southwest (FRCSW) have developed an on-site 3D printing process to create composite repair patches for the F/A-18 Super Hornet. Specially shaped patches are printed using industrial 3D printers and then mounted, cutting repair time by 50% compared with conventional methods. The previous approach often required dismantling and shipping parts from remote bases to repair facilities in the USA, or flying specialized technicians to perform repairs on site, leaving jets grounded for extended periods. The Navy says the new patches are durable and will undergo validation beyond lab tests. Initial practical tests in operational flight settings are planned for summer 2026.