The RAF has 3D printed a replacement part and fitted it to a Eurofighter Typhoon for the 1st time
August 11, 2025
The UK Royal Air Force (RAF) has successfully installed an in-house manufactured 3D printed part in an operational Eurofighter Typhoon for the first time.
Specialists from No 71 Inspection & Repair Squadron manufactured the component at the Hilda B. Hewlett Centre. It was then installed by No 29 Squadron engineers on the Typhoon on 7 August at RAF Coningsby.
While the fix isn’t permanent, it shows the potential for additive manufacturing to keep aircraft operational while replacement parts are awaited.
“When aircraft are grounded waiting for spare parts, we can’t afford delays,” says Squadron Leader John Mercer, Senior Engineering Officer at No 29 Squadron. “Being able to print our own temporary components means getting jets back in the air faster.”
The first 3D printed Typhoon part is installed on a jet
The RAF’s 3D-printed component replaced a temporary anti-yaw spigot in the pylon assembly on a Typhoon fighter.
The pylon assembly is the structure that attaches weapons or fuel tanks to the aircraft’s wing. The anti-yaw spigot is a small but critical part within that assembly that helps keep the pylon stable and aligned under aerodynamic loads, preventing unwanted twisting or movement (“yawing”) when the aircraft is flying or manoeuvring.
In this case, the original spigot was damaged. While the manufacturer worked on a permanent replacement, No 71 Squadron scanned the damaged piece, designed a substitute, and 3D-printed it to get the jet back in service quickly.
“This technology offers enormous potential to maintain our aircraft faster than ever before,” says Wing Commander Gemma Lonsdale, Officer Commanding Air Wing Engineering at RAF Coningsby. “The 71 Squadron team has been exceptional – their expertise and collaboration made this milestone possible.”
Wittering: The RAF’s hub for additive manufacturing
The Hilda B. Hewlett Centre for Innovation was inaugurated in October 2022, and is equipped with advanced additive manufacturing and scanning technologies. It is part of the No 71 Inspection and Repair Squadron based at RAF Wittering
This includes a Wayland Additive Calibur3 3D printer, one of the most advanced machines for additive manufacturing. There is also a Nikon HTX 540 CT scanner, which can examine objects in minute detail.
Renishaw’s RenAM 500 metal printer and a Stratasys Fortus 450 polymer printer provide reliable 3D printing capabilities, which perfectly complement the Wayland and Nikon machines.
71 (Inspection & Repair) Squadron operates within the RAF’s A4 Force, specialising in structural repairs to the UK’s fixed-wing military aircraft. The unit’s in-house design team develops bespoke repair solutions for situations where standard methods are impractical or unavailable.
