U.S. Navy Flight-Tests 3D-Printed Composite Repairs for F/A-18 Super Hornets

An F/A-18 Super Hornet pilot prepares for flight at Fleet Readiness Center Southwest in San Diego. The Navy is testing a new 3D-printed composite patch repair method developed by the facility and the Naval Air Warfare Center Aircraft Division that is designed to cut F/A-18 repair times in half at forward operating bases.

July 7, 2026

The U.S. Navy is flight-testing 3D-printed composite replacement parts to evaluate their potential to reduce the time required to complete composite repairs across its F/A-18 Super Hornet fighter jet fleet.

The Naval Air Warfare Center Aircraft Division (NAWCAD) and Fleet Readiness Center Southwest (FRCSW) are focused on reducing F/A-18 Super Hornet composite repair time by approximately 50 percent. The reduction could be achieved through a 3D-printing repair method that enables sailors to perform composite fixes directly at forward operating bases.

"Our goal is to put capability directly into the hands of the Fleet," said NAWCAD Commander Rear Adm. Todd Evans. "By simplifying a complex repair so it can be done forward, our engineers would get aircraft back in the fight faster — it’s a smart solution that makes our squadrons more self-sufficient and directly improves operational readiness."

The F/A-18 Super Hornet is a multirole fighter that serves as the backbone of the Navy’s carrier-based air operations.

After successful laboratory and ground testing, the joint development team plans to flight-test the 3D-printed repair on an operational aircraft this summer.

When an F/A-18 is grounded by damaged composite components — such as engine bay doors — the Navy loses critical combat capability. Historically, repairing these advanced materials has caused significant delays. The traditional process requires highly specialized maintenance artisans and lengthy turnaround times, keeping aircraft out of service and adding strain to supply chains.

To address the challenge, NAWCAD and FRCSW engineers created high-performance, 3D-printed composite patches that can be applied directly to the aircraft. The team also developed patch-application procedures and quality checks to ensure the printed parts are safe for flight.

The solution could leverage a network of 3D printers already deployed at 22 Navy maintenance sites worldwide, enabling repairs where aircraft operate rather than waiting for parts to be shipped back to U.S. repair depots.

The 3D-printed composite repair approach is one of the Navy’s latest additive manufacturing investments. In May, FRCSW hosted top Navy officials for a tour demonstrating how additive manufacturing technologies, including cold spray, are transforming maintenance and repair capabilities across the service.

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