Chinook helicopter components manufactured by additive manufacturing undergo flight testing

MH-47G Chinook helicopters at Fort Campbell, Kentucky, USA, were fitted with two 3D printed cargo links for ongoing flight testing. As part of the National Center for Defence Manufacturing and Machining's (NCDMM) AMNOW initiative, the cargo links are made of a high-strength aluminium alloy 7A77.

The MH-47G bears a striking resemblance with the Boeings' flagship CH47 Chinook twin rotor helicopter, with a bit of upgrade. The use of aluminium alloys in making aerospace components is essential because of their negligible weight and corrosion resistance properties.

The AMNOW programme was founded in 2019 by NCDMM and partners, focusing mainly on the inclusion of AM technology into the prevailing U.S army supply chain. These cargo links will be the first army-instigated in-house metal additively manufactured aircraft components to be installed in army aircraft.

Some significant contributors to this venture were the United States Army Combat Capabilities Development Command (DEVCOM), Aviation & Missile Center (AvMC), and other major suppliers.

HRL developed and provided the aluminium powder, while Beehive Industries contributed with additive manufacturing. Penn United Technologies applied their machining and finishing expertise, followed by Product Evaluation Systems evaluating the quality of products with material testing. Lastly, Pinnacle Industrial X-ray Laboratory offered to induce radiographic inspection.

The AMNOW functional team comprises The Barnes Global Advisors, Catalyst Connection, Quotient, GCA Coach, NCDMM, Advanced Engineering Solutions, LECS Energy, the University of Alabama-Huntsville and Youngstown Business Incubator.