The United States Air Force’s Hill Aerospace Museum is using 3D scanning and printing to preserve aviation history, streamline restoration, and modernize exhibits. By fabricating rare or obsolete components in-house, the museum has reduced costs and ensured historically accurate aircraft displays.
“Ensuring historical accuracy is at the forefront in restoration and exhibits,” said Brandon Hedges, museum restoration chief. “Our priority is to find the historically accurate part; if we are unable to find the correct part, that’s when we turn to modern technology to recreate our part for visual purposes.”
Preserving Authenticity Through Technology
Hill Aerospace Museum said that a $6,000 investment in 3D technology has cut project costs by about 80% and eliminated months of searching for rare parts by producing accurate, reliable reproductions in-house.
Hedges explained that the team first conducts extensive research and reaches out to the wider aviation community to locate original components. When originals cannot be sourced, technicians use measurements, scans, and historical references to produce accurate reproductions. “It takes careful adjustments, correct lighting, and steady movements to create the perfect model. These models can then be 3D printed to replace the fragile or missing components of a plane,” Holly Bingham, who works with the restoration team, said.
Hedges emphasized that every printed part is carefully tracked so an original can be substituted if it becomes available later, maintaining both authenticity and historical integrity.
Beyond Restoration: Practical Applications
The museum has discovered that 3D technology extends beyond aircraft restoration. Exhibit specialist John Sluder highlighted its practical applications, such as producing static sign mounts that prevent informational signs from sliding on concrete floors while allowing quick repositioning.
“What excites me most is that 3D printing isn’t just helping us restore aircraft parts,” Sluder said. “It’s giving us tools to solve everyday challenges in the museum, from keeping exhibits safe to making signage more flexible. In the end, it means we can preserve history more effectively and share the Air Force story with future generations in ways that are sustainable and adaptable.”
A Growing Trend Across Museums
Hill Aerospace Museum’s use of 3D technology is part of a broader trend in heritage preservation.
In April, UK historic site Coventry Charterhouse unveiled 3D printed replicas of two 14th-century statues—St. Denis and St. Lawrence—created in collaboration with the Manufacturing Technology Centre (MTC). The replicas were meticulously created using detailed digital scans and 3D modeling, followed by the precise process of layer-by-layer printing, ensuring an exact reproduction of the original sculptures.
Similarly, for the London Natural History Museum’s 150th anniversary, a new gallery for the ‘Fixing Our Broken Planet’ exhibition was outfitted with display cases made in collaboration with NHM staff and LAMÁQUINA, a Barcelona-based 3D design studio. The cases used 3D printed ceramics made from recycled clay and biopolymer joints, preserving the gallery’s Victorian features while integrating sustainable materials.
The 3D printing process enabled the precise production of 1,686 modular components in just three months. Robotic fabrication and careful monitoring ensured dimensional accuracy within 5 mm, accommodating cables, signage, and strict installation requirements.
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Featured image shows Brandon Hedges, Hill Aerospace Museum’s restoration chief, describes how 3D printers were used to restore the F-117 Nighthawk. Photo via Hill Aerospace Museum.
