Saab Innovates: Testing 3D-Printed Components on Gripen for Rapid Battlefield Repairs
Saab has successfully accomplished a trial that signifies the inaugural instance of an external 3D-printed component being utilized on a Gripen, rather than internal 3D-printed elements. The objective of this experiment was to assess how additive manufacturing could facilitate battlefield damage repair.
The test flight occurred above Saab’s facilities in Linköping, Sweden, on Friday, March 19th. The Gripen was outfitted with a replacement hatch that was 3D-printed utilizing additive manufacturing with a nylon polymer known as PA2200. This advancement represents a significant move towards employing 3D-printed spares for expedited repairs to fighter jets that have experienced damage during remote operations, thereby providing a crucial time-saving advantage.
As there was no 3D model of the original hatch, it was detached from the aircraft and scanned, enabling the 3D printing of an exact replica customized for this specific aircraft.
“The initial post-flight examination of the hatch was very encouraging, revealing no visual structural alterations from the flight. The potential of this approach indicates that maintenance staff in the field can access custom-fitted spare parts, eliminating the need for emergency repairs or cannibalizing other grounded aircraft for parts, while also minimizing the limited number of components taken on deployment. This further decreases operational downtime during repairs,” states Håkan Stake, contract manager for Gripen C/D support and manager of the development project.
To realize the objective of deploying this capability, additional testing along with agreements on material standards is essential.
This achievement marks the latest progression in Saab’s adoption of additive manufacturing. In 2017, Saab co-founded the AMEXCI consortium with the specific aim of advancing this technology, and they have since collaborated with AMEXCI’s specialists to explore new applications and methodologies for producing parts and equipment through additive manufacturing.
“This test flight of a component with operational significance is a vital milestone, as an aircraft—and its components—must consistently meet stringent airworthiness standards. In terms of enhancing operational availability in the field, additive manufacturing will be transformative,” remarks Ellen Molin, senior vice president and head of Saab’s business area Support and Services.
The subsequent steps for Håkan Stake and his team involve examining alternative materials to PA2200 that are also flexible and capable of withstanding frigid conditions at high altitudes. They will also advance a container solution, allowing for the transportation of printing equipment on deployments.
