The Royal Netherlands Air Force is the guardian of the Dutch skies, with a fleet that includes various helicopters, fighter jets, and large cargo planes. Many of these aircraft have unique, customized parts that are difficult to replace with off-the-shelf components—this is where the opportunity for them to use Ultimaker 3D printers arose.
The Woensdrecht military base is the main maintenance facility for the Royal Netherlands Air Force, where staff conduct regular maintenance and repairs on aircraft such as Chinooks, Apaches, NH90s, and F16s. The base also houses the Royal Netherlands Air Force Academy, Koninglijke Militaire School Luchtmacht (KMSL).
"There are many special components in the air force, so it is essential to manufacture tools ourselves," Bas emphasized.
．Academy Workshop: MakAIRsJop
Bas Janssen is a member of the Ambition Innovation Results (AIR) department, 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 find new solutions to various work challenges. Initially, Bas started holding workshops using multiple Ultimaker 3D printers. After quickly familiarizing themselves with the software and hardware, they realized this was an opportunity to improve the speed and efficiency of maintenance at the air force base.
"People who use 3D printing often don't have a technical background. Thanks to the rapid advancement of technology, they now only need about three hours of training to start solving problems they encounter in their work."
．Accessories, Tools, and Fixtures
Maintaining customized aircraft with complex structures is a huge challenge, involving many uncommon parts and systems. 3D printing can make the job simpler. For making these specific-purpose tools, it provides a more economical method. Bas and his team quickly discovered that by using 3D printed parts instead of outsourcing custom orders over the past two years, they could effectively save time and money.
For example, when transporting jet engines, certain openings need to be covered with special caps. These custom parts are expensive and have long lead times, but using an Ultimaker for 3D printing only takes about two hours.
We use Ultimaker's best precision for 3D printing tools, jigs, 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 a simple 3D-printed aid (further reading: A Glimmer of Hope for Children with Spinal Muscular Atrophy), these details can be adjusted before the parts are installed onto the helicopter, saving several hours per aircraft.
For some metal parts that require CNC machining in later stages, the Ultimaker 3D printer facilitates early-stage prototyping and iterative testing, allowing for quick and cost-effective design iterations before the final CNC parts are produced.
．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: "New Generation Smart Manufacturing Dream Car" Tour); they even purchased 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 period for cadets to truly become the 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; this way, air force engineers can directly manufacture the tools they need internally.
What are the 6 major benefits that Ultimaker 3D printers bring to the Royal Netherlands Air Force?
．Manufacturing complex parts
．Customized adjustment tools
．Meeting immediate testing and development needs
．Assisting with preliminary work for metal parts
．Easy to operate, quick to learn
．Efficient and cost-saving internal manufacturing
Want to see the Ultimaker 3D printer in action? The "New Generation Smart Manufacturing Dream Car" tour is currently making its way around Taiwan. Quickly check the nearest schedule for you. There will also be free coffee and gifts on-site!
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 tirelessly!
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