LAUGHLIN AIR FORCE BASE, Texas -- In the world of pilot training, mission readiness starts on the ground level. The 47th Flying Training Wing Maintenance Directorate (MXD) are advancing their maintenance capabilities using manufacturing tools like 3D printing and 3D scanning to keep aircraft flying, combatting supply chain shortages and an aging fleet.
The directorate’s Components Maintenance division has built a reputation for innovation by blending traditional repair techniques with new technology. Their approach allows Laughlin to maximize aircraft availability, reduce downtime and meet annual pilot training requirements.
“We’re not just repairing aircraft, we’re creating solutions,” said Lt. Col. Wesley Wade, 47th FTW director of maintenance. “When supply chains fall short, we step in with local manufacturing to keep our fleet mission-ready.”
That effort includes corrosion control, non-destructive inspections and component overhauls that extend the life of vital systems like hydraulics and pneumatics. The directorate fabrication shop also restores structural elements and aerodynamic surfaces, ensuring the fleet’s safety and performance.
In addition to the traditional maintenance efforts of keeping Laughlin’s trainer aircraft fleet mission ready, the real game-changer is the unit’s investment in 3D scanning, CAD/CAM software and additive manufacturing. By reverse engineering obsolete parts, particularly for the advanced pilot trainer, T-38C Talon, maintainers can quickly reproduce components no longer available through traditional suppliers, ensuring continued operations.
This capability enables rapid prototyping, validates designs before production and integrates with Computer Numerical Control (CNC) machining for streamlined manufacturing.
Recently the MXD has completed projects demonstrating their ability to respond to fleet-wide requirements and adapt their manufacturing capabilities to meet evolving needs. They have produced in-house flex hoses to support T-6A Texan II and T-38 fleets and designed specialized seat dollies for T-6 Crash Survivable Recorders.
The MXD’s fabrication capabilities, extend beyond Laughlin, supporting other Air Force and Department of Defense units through the Air Force Repair Enhancement Program (AFREP), boosting fleet readiness across the service.
“Every part we produce in-house represents time saved and missions completed,” said Master Sgt. Michael Senn, 47th MXD components division superintendent. “It’s about ensuring our pilots have the aircraft they need, when they need them.”
By embracing 3D printing and local manufacturing, Laughlin’s maintainers are helping the base keep pace with the demands of modern training while ensuring aircraft remain ready for years to come.