Case Study: United States Air Force achieves rapid on-demand part replacement and improved readiness with 3D Systems' Figure 4™

Ultra-fast print speeds and material versatility of Figure 4™ platform serve as runway for anticipated research into lean inventory control for U.S. Air Force

3D Systems, together with the University of Dayton Research Institute (UDRI) and under the America Makes MAMLS program, is tackling a key USAF sustainment challenge: aging legacy aircraft with many out-of-production, low‑criticality parts (connectors, knobs, grommets, spacers) that create logistics delays and high costs. The project seeks practical, fast, and reliable maintenance solutions to improve readiness and reduce reliance on scarce legacy supply chains.

The team is evaluating 3D Systems’ Figure 4™ Digital Light Processing workflow—3D scan-to-CAD, rapid DLP printing, and tailored photopolymer materials—while collaborating with Lockheed Martin and Northrop Grumman for validation. Early work shows promising manufacturing-grade repeatability and very fast print speeds; over the next two years the program will complete material qualification, testing, and recommendations to enable on‑demand part replacement and potentially same‑day repairs, with final qualification still pending.

United States Air Force