The Royal Netherlands Air Force is the guardian of Dutch skies, with a fleet that includes various helicopters, fighter jets, and large cargo aircraft. These aircraft have many unique, customized parts that are difficult to source off-the-shelf—thus opening up a new opportunity for them to use Ultimaker 3D printers.
The military base at Woensdrecht is the primary maintenance hub for the Royal Netherlands Air Force, where personnel conduct regular maintenance and repairs on various aircraft models such as Chinooks, Apaches, NH90s, and F16s. The base is also home to the Royal Netherlands Air Force Academy (Koninklijke Militaire School Luchtmacht - KMSL).
“There are many special components in the Air Force, so manufacturing tools ourselves is a necessity,” Bas emphasized.
．Academy Workshop: MakAIRsJop
Bas Janssen, a member of the Ambition Innovation Results (AIR) department, is dedicated to acquiring knowledge of the latest technologies such as laser cutting and 3D printing, and sharing it with colleagues. To achieve this goal, he established a research workshop within the Royal Netherlands Air Force: MakAIRsJop.
His workshop helps students and engineers provide new solutions to various work challenges; initially, Bas began by holding workshops using multiple Ultimaker 3D printers. After quickly becoming proficient with the software and hardware, they realized this was an opportunity to improve the speed and efficiency of maintenance at the air base.
"People using 3D printing often don't have a technical background. Thanks to the rapid advancements in technology, nowadays, with just about three hours of instruction, they can start solving problems they encounter in their work."
．Accessories, Tools, and Fixtures
Maintaining complex, customized aircraft is a huge challenge, covering many uncommon parts and systems, and 3D printing can make the work simpler. For producing these specific-purpose tools, it offers a more economical method. Bas and his team quickly discovered that in the past two years, using 3D printed parts instead of outsourcing custom fabrication effectively saved time and money.
For example, when transporting jet engines, certain openings need to be covered with special caps. These custom-made items are expensive and have long lead times, but 3D printing them using an Ultimaker only takes about two hours.
We use Ultimaker for the best precision in 3D printing tools, fixtures, and prototypes.
Ultimaker 3D printers are also used to produce specialized adjustment tools. For instance, some helicopter parts are difficult to configure during installation. By utilizing simple 3D printed aids (further reading: A Ray of Hope for Children with SMA: Exoskeleton Supportive Parts), these details can be adjusted before the parts are installed on the helicopter, saving hours for each aircraft.
Furthermore, some metal parts must be completed with CNC machining in the later stages. With Ultimaker 3D printers for early-stage prototype design and iterative testing, they can quickly and cost-effectively replace designs before the final CNC parts are manufactured.
．3D Printing - A New Technology Taking Off
After initial success in the workshops, the Royal Netherlands Air Force began to expand its 3D printing activities (further reading: "Next-Generation Smart Manufacturing Dream Tour Vehicle"); they even acquired an Ultimaker S5 for their 3D printing workshop to print larger parts (further reading: Ultimaker S5 Large Size Test) and use the latest materials and hardware.
Bas now suggests that every air force maintenance point should utilize 3D printing technology. "The crucial transition for cadets to truly become a fifth-generation air force is when they realize they don't have to limit themselves and can make changes now. And Ultimaker can do this, helping people understand what 3D printing technology can do for them now—without a long learning process. Today's software and hardware can help people turn ideas into reality."
His team will be able to share 3D models, create new designs, and support internal colleagues with 3D printing; in this way, Air Force engineers can directly manufacture the tools they need in-house.
What are the 6 major benefits that Ultimaker 3D printers bring to the Royal Netherlands Air Force?
．Manufacture complex parts
．Customized adjustment tools
．Meet immediate testing and development needs
．Aid in preliminary work for metal parts
．Easy to operate, quick to learn
．Efficient in-house production, more cost-effective
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Still considering integrating 3D printing technology into your workflow? Explore more application cases of 3D printing technology: Recruiting 50 Super Teammates! Rushing to Meet Deadlines Day and Night!
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