At The United Kingdom’s Royal Air Force (RAF) Coningsby in Lincolnshire, engineers have used additive manufacturing (AM) to produce a temporary pylon assembly part, enabling a Typhoon jet to return to service while a permanent replacement is developed. The process began with precision-scanning the damaged component and sharing the data with the original manufacturer and 71 Squadron to design and approve the interim solution.
Air Vice-Marshal Shaun Harris, Director Support, HQ Air, said the achievement represents a key milestone in the RAF’s efforts to make AM a core capability and warfighting enabler. “Without the use of this technology, local innovation and RAF engineers’ operational mindset, this aircraft would have been unusable for many months. In the coming months, Air Support will share detailed plans for the expansion of such capabilities, to enhance our agility and readiness to fly and fight.”
From Research to Operational Capability
Initial funding in 2022 supported exploration of 3D printing for producing aircraft and equipment components securely and on demand. This work evolved into RAF Advanced Manufacturing Exploitation (RAF AM-X), now a proven capability demonstrating both technical and operational success.
Originally launched as Project Warhol under 71 (IR) Squadron, RAF AM-X has now expanded across the Support Force. The team produces both polymer and metallic components for platforms including the F-35 Lightning, A400M, Chinook helicopter, and Mk 15 helmets, and is developing a 3D printed metallic chaff and flare dispenser for the Apache, Wildcat, and Shadow aircraft.
The RAF also collaborates with the Manufacturing Technology Centre (MTC) through the High Value Manufacturing Catapult initiative, as well as with Five Eyes and NATO allies, advancing AM to support Agile Combat Employment and Transition to Conflict strategies. “While AM-X will not be suitable for every application, it is providing a paradigm shift for aircraft manufacturing and maintenance. AM-X will generate significant operational advantage, increase supply chain resilience, mitigate obsolescence, and ultimately increase fleet availability – all vital tools enhancing the RAF’s ability to ensure sustainment while maximising combat mass,” said Group Captain Justin Blackie, Programme Director for RAF AM-X.
Expanding Innovation Across the Force
Beyond AM-X, other RAF initiatives are using 3D printing in daily operations. The Chinook Support Centre is developing a certified modification with a 3D printed cockpit transceiver mount. Meanwhile, the ASTRA innovation programme equips RAF Innovation Hubs with 3D printers, allowing personnel to gain basic design and fabrication skills for local applications.
In addition, RAF AM-X plans to publish a white paper in early 2026, detailing the RAF’s full AM strategy and guiding upcoming developments.
3D Printing in the UK Armed Forces
The UK is investing in 3D printing to rapidly produce spare parts, enhancing operational readiness across land, sea, and air forces. In the Army, units such as the 5 and 9 Battalions of the Royal Electrical and Mechanical Engineers (REME) use 3D printing to support operations, including producing parts for Ukraine.
In 2024, Theatre Support Battalion (9 REME) applied its AM capabilities during Exercise Steadfast Defender, NATO’s largest military exercise since the Cold War, using an XSPEE3D metal cold-spray 3D printer from Australian company SPEE3D. The team produced a variety of spare parts, such as jerry can caps, communication brackets, and engine bay mounts for older vehicles.
The 71 Inspection and Repair (IR) Squadron at RAF Wittering also operates several metal 3D printers to quickly manufacture aerospace components. As part of Project Warhol, the squadron uses machines including the Wayland Additive Calibur3 NeuBeam, Renishaw RenAM 500 metal LPBF, and Stratasys Fortus 450 FDM, supported by a Nikon HTX 540 CT scanner. These systems enable rapid production of parts for repairs, testing, and trial applications.
Help shape the 2025 3D Printing Industry Awards. Sign up for the 3DPI Expert Committee today.
Ready to discover who won the 2024 3D Printing Industry Awards?
Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.
Featured photo shows Fitting of the first 3D printed part on a Typhoon. Photo via Royal Air Force (RAF).
