The U.S. Air Force is making significant strides in enhancing the efficiency of its C-17 Globemaster III military transport aircraft through the final evaluation phase of 3D-printed drag reduction components. This innovative project revolves around the implementation of specialized microvanes, designed to reduce drag by one percent, thereby lowering fuel consumption.
Each microvane, which boasts dimensions of 4 x 16 inches (10.1 x 40.6 centimeters), is secured to the aircraft’s fuselage using a robust adhesive. The strategic installation of dozens of these blades on the C-17 serves to modify the aircraft’s aerodynamic profile, addressing disruptions caused by the inherent design of its cargo door section. The anticipated benefits of this technology extend beyond performance enhancements; it is expected to yield a return on investment within a mere seven months and save the Air Force over $14 million annually.
Roberto Guerrero, the Deputy Assistant Secretary for Operational Energy, Safety, and Occupational Health with the U.S. Air Force, emphasized the importance of every gallon of fuel saved in bolstering operational readiness and effectiveness. “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,” Guerrero noted.
The final live testing phase for the microvanes took place in October 2023, which included simulations of various missions like assault strip operations and air refueling tasks. The C-17 involved in these demonstrations retained the newly installed blades, marking it as the first Globemaster III to utilize this cutting-edge technology. This particular aircraft is stationed at the Stewart Air National Guard Base in New York.
Lt. Col. Eric Durkins, commander of the 105th Aircraft Maintenance Squadron at Stewart, remarked on the collaborative efforts between different units, stating, “We paired up with Memphis ANGB, which increased process knowledge across both wings.” He acknowledged the pivotal role of maintainers working in tandem with the engineering team to establish the installation procedures for the C-17 fleet, highlighting that the aircraft has successfully supported missions worldwide for over a year without any issues, including deployments in various operational areas.
Currently, six C-17s are equipped with the 3D-printed microvanes, undergoing logistics service assessments before a potential widespread rollout across the entire Globemaster III fleet. Following the integration of microvanes on two additional aircraft, a comprehensive six-month evaluation will commence at Charleston Air Force Base in South Carolina.
Guerrero reiterated the significance of this collaboration, stating that it underscores how partnerships propel mission objectives forward. He added, “It’s about ensuring that we remain agile and capable in a rapidly evolving global environment.” Additionally, recent legislative measures allow for the redirection of savings generated by such technological advancements to support other initiatives aimed at enhancing combat capability.
