The US Air Force has entered the final evaluation phase of 3D-printed drag reduction components for its C-17 Globemaster III military transport aircraft.
The project is centered on specialized microvanes that decrease drag by one percent and cut fuel consumption.
Each of these devices resembles a thin blade measuring 4 x 16 inches (10.1 x 40.6 centimeters), which is installed with a strong adhesive at the rear of the fuselage.
Dozens of the blades attached to the C-17 modify the plane’s aerodynamic profile, which is disrupted by its cargo door section design.
The technology is expected to yield a return on investment within seven months upon adoption and save the air force more than $14 million annually while enhancing the aircraft’s performance.
“Every gallon of fuel saved strengthens our readiness and operational effectiveness,” US Air Force Operational Energy, Safety, and Occupational Health Deputy Assistant Secretary Roberto Guerrero explained.
“By adding modern technology like microvanes to our legacy aircraft, we’re saving millions in fuel costs and building capability critical for maintaining our competitive edge in the era of Great Power Competition.”
First Equipped C-17 Operational
Final live testing of the microvanes was conducted in October 2023, with simulations involving assault strip and air refueling tasks.
The C-17 used in the demonstration retained the blade installation and became the first Globemaster III unit to employ the technology.
The plane is stationed at the Stewart Air National Guard Base in New York.
“We paired up with Memphis ANGB, which increased process knowledge across both wings,” Stewart Air National Guard Base’s 105th Aircraft Maintenance Squadron Commander Lt. Col Eric Durkins stated.
“Our maintainers, working side by side with the engineering team from the start of this project, helped develop the installation procedures for the C-17 enterprise. The aircraft has supported our worldwide missions now for over a year without an issue, to include an [Area of Responsibility] deployment.”
Fielding Soon
Six C-17s are now equipped with the 3D-printed microvanes for the devices’ logistics service assessment prior to fielding across the air force’s entire Globemaster III fleet.
After integration for two more planes is complete, the evaluation will begin at Charleston Air Force Base in South Carolina for six months.
“This collaboration highlights how partnerships drive forward our mission objectives,” Guerrero said.
“It’s about ensuring that we remain agile and capable in a rapidly evolving global environment. What’s more, through recent legislation, we can use the savings realized by this technology to fund other initiatives that increase combat capability.”
