US technicians have found a way to save millions of dollars on the maintenance of F-35 Lighting II fighters using plastic and a 3D printer

The cost of the F-35 program, including production and development, has already topped $400 billion and will reach $1.3 trillion over 77 years. The three experts at Hill Air Force Base have found a way to save some money.

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Technicians at the Hill Base workshop have been able to develop a cover that will save millions of dollars in maintenance costs for fifth-generation fighter jets. It is designed to protect sensors when the aircraft is on base.

The F-35 Lightning II has two groups of sensors mounted on the right and left sides of its nose. The sensors are used to collect information that can affect aircraft parameters during flight.

When the fighter is on the ground the sensors must be covered to protect against moisture and dust. A special tool with rubber seals is used for this purpose. Service personnel say the seals lose their ability in hot weather and the pins often break. Yet such a tool costs over $600 per unit.

Technicians at the Hill-based workshop created a cheap cover printed on a 3D printer. Then they fitted magnets. The new design sticks securely to the body of the F-35 and protects the sensors in the event of rain, snow, wind and hail. In addition, the cover is universal, so it can be installed on either side of the nose section.

The job takes approximately 22 hours. One cover costs $45, which is more than ten times cheaper than the original tool. The technicians say they are capable of making any colour lid and putting the squadron's logo on it. The U.S. Air Force is now trying to get a patent for the new design.

Source: Air & Space Forces Magazine