Case Study: U.S. Air Force cuts C-17 fuel costs with Stratasys 3D printed microvanes

3D Printed Microvanes Help the U.S. Air Force Cut C-17 Fuel Costs by $14 Million Annually

The U.S. Air Force faced a challenge with its C-17 Globemaster III fleet, where aerodynamic drag from the aircraft's upswept cargo-door section was increasing fuel consumption and limiting mission efficiency. They needed a low-cost modification to improve fuel efficiency without disrupting operations and partnered with vendor Stratasys for a solution.

Stratasys provided a solution using 3D printed microvanes, which were manufactured on an F900 3D printer with Antero 800NA aerospace-grade thermoplastic. These devices were bonded to the aircraft's exterior to reduce drag. The solution resulted in a 1% reduction in drag and fuel consumption, which is projected to save the U.S. Air Force over $14 million annually and deliver a return on investment within just seven months.

U.S. Air Force