BARNES AIR NATIONAL GUARD BASE, Mass. – Innovation, improvement, and efficiency lie at the forefront of the mission for every Barnestormer. In the Metals Technology Shop, Master Sgt. Travis Miller, metals technology supervisor, and Staff Sgt. Ryan Krasnecky, metals technology journeyman, has increased productivity and reduced costs through 3D printing at the 104th Fighter Wing and throughout the Air National Guard.
When the wing acquired the 3D printer in Sept. 2022, Miller began outlining various projects and opportunities where the wing could benefit from 3D-printed objects. Miller also saw the potential for the 3D printer to effectively decrease or remove hazards in the work environment by developing more effective tools and equipment to accomplish a task.
“The possibilities with this machine and this technology are really endless and only limited to the imagination,” said Miller. “If anyone comes up to me and has an idea for something we could 3D print that could potentially save us time and money, we work together and find a way to get it done.”
One of the first projects that Miller aimed to accomplish with the 3D printer was creating a lightweight and durable ammo container at a cheaper cost to manufacture than outside companies.
Existing ammo containers either store ammunition in plastic bags or cardboard boxes with foam inserts, creating a risk of the ammunition becoming damaged or lost. However, 520 hours of printing time and 59.16 pounds of filament later, the Metals Technology Shop was able to create 100 strong and lightweight ammo containers that solved this problem and at a fraction of the cost.
Another tool that the shop was able to 3D print that strengthened the effectiveness of the wing is a pressure valve tool that is utilized by the crashed, damaged, disabled aircraft recovery (CDDAR) team, which provided the team with an efficient way to remove and install the pressure valves needed to inflate and deflate the aircraft bags used to stabilize damaged aircraft during recovery.
Senior Master Sgt. Michael Land, 104th Fighter Wing CDDAR team chief, emphasized the effectiveness of the 3D printed valve tools through their ability to increase the CDDAR team’s speed during recovery exercises.
“The relief valve tool significantly enhances CDDAR operations by streamlining the installation and removal process, which directly increases response speed, enabling faster and more agile mission execution,” Land said.
Krasnecky, who has worked in the Metals Technology Shop since 2019, said, “what I’ve learned since being in Metals Technology is that we have a tremendous amount of capability to create parts or tools that are essential to base operations.” “Solving a problem or making an idea come to life is a rewarding part of what we do on a daily basis.”
The 3D printer has also been used to create tools and parts that support flying operations. For example, the older versions of the F-15 targeting pod cradles did not fit the F-15 targeting pod directly, which would cause imbalance and potential hazards in transporting the $500,000 pod. With the 3D-printed targeting pod cradles, the innovative design ensures the targeting pod will not be damaged or destroyed for less than $20 per cradle.
Similarly, the Metals Technology Shop also created a 3D-printed chaff and flare holder for the wing, which provides Airmen with a safer and more durable method for transporting, installing, and removing chaff and flare from aircraft.
As a member of the Massachusetts Air National Innovation Team (MANGIT), Miller meets with Massachusetts Air National Guard and Army National Guard leadership monthly to review innovation ideas with other units and bases. Miller acknowledges the importance of sharing new ideas with other units as technology improves.
“I always look to reach out and share our successes with others and show them projects we have done to spark interest,” Miller said. “It’s all about finding ways to help out and share your improvements.”