The United States Marine Corps, in collaboration with the Naval Air Systems Command’s (NAVAIR) Additive Manufacturing (AM) Integrated Product Team (IPT), has made a breakthrough with the introduction of the first Suitable Substitute Engineering Change Proposal (ECP). This innovative initiative, designed to address persistent issues like material shortages and lengthy production delays, is a significant step forward in improving logistics and part replacement across the fleet.
The AM IPT, which was established in 2016, focuses on revolutionizing part production through additive manufacturing, also known as 3D printing. This approach allows the Navy to quickly produce necessary parts on demand, avoiding the traditional delays and high costs associated with centralized mass production. For the Marine Corps, this could mean faster deployment of crucial components, particularly in cases where time-sensitive replacements are needed to keep aircraft and equipment operational.
AM IPT’s Strategic Role
NAVAIR’s AM IPT includes a team of 20 individuals, with nine members from the Naval Air Warfare Center-Aviation Division’s Modeling and Design Branch. The team aims to provide a more efficient and responsive system for part replacements, particularly for non-critical components that previously faced delays due to the lengthy ECP process.
Instead of relying on large-scale manufacturing at centralized facilities, the AM IPT facilitates the production of smaller quantities of parts as needed. This approach is particularly useful for parts that have become obsolete or face material shortages. In the past, this process was unfeasible due to the long lead times required for configuration management and the high costs associated with it. However, additive manufacturing has proven to be a viable solution, enabling the rapid delivery of parts to the fleet.
Marine Corps Commandant Gen. Eric Smith highlighted the importance of advanced logistics capabilities in a statement on August 29. “The myriad unmanned subsurface, surface, and aerial systems that the Joint Force is rapidly procuring are a perfect match for our well decks and flight decks,” he said, adding that amphibious ships are particularly well-suited for deploying advanced technologies like additive manufacturing and 3D printing. This capability could dramatically improve the Marine Corps’ ability to sustain operations in contested environments.
Identifying the Right Candidate for the Suitable Substitute ECP
The success of the Suitable Substitute ECP hinged on finding the right part for this new process. The H-1 Fleet Support Team (FST), in coordination with PMA-276, worked closely with the AM IPT to address a supply issue affecting the UH-1Y helicopter’s rescue hoist chain guard cover.
Kevin Tierney, the H-1 FST Support Equipment Systems Lead Engineer, described the work that went into evaluating the part. “We did a lot of work behind the scenes to determine if the guard cover could be reliably 3D printed,” he explained. The team reverse-engineered the original part, took precise measurements, developed a CAD model, and conducted test prints to ensure the cover would fit properly on the hoist.
Once this data was gathered, the AM IPT developed a technical data package (TDP), which is essential for configuration management. The TDP included technical qualifications and certifications of the 3D-printed part, allowing the NAVAIR Configuration Management team to create an abbreviated Class I Suitable Substitute ECP. Remarkably, the team completed this process in just 10 days at a cost of $1,700, compared to the traditional ECP process, which can cost up to $300,000.
Approval and Implementation of the Suitable Substitute ECP
The final step in the process involved submitting the ECP for approval through NAVAIR’s Enterprise Change Management (ECM) system. On August 12, PMA-276 uploaded the ECP and accompanying TDP, which was quickly reviewed and approved. Less than two weeks later, the program office received its first Suitable Substitute ECP implementation letter, officially allowing the 3D-printed hoist chain guard cover to be used by the fleet.
The UH-1Y rescue hoist chain guard cover is considered a non-critical part, making it an ideal candidate for the Suitable Substitute ECP process. With the approval in place, the H-1 FST began updating maintenance manuals to reflect the new AM part as an acceptable replacement. This change means that when an H-1 squadron faces delays in ordering the original part, they can now request the 3D-printed version from their supporting Marine Aviation Logistics Squadron (MALS). Some MALS units already have AM capabilities, and 3D printers can even be deployed with Marine Expeditionary Units (MEUs), allowing the chain guard cover to be delivered to the fleet within days.
Historically, replacing this part could take up to a year due to stock shortages, but the new process drastically reduces that time. Mike Medlin, the H-1 FST Lead Engineer, noted the improvement: “Now we can print covers and provide them to the squadron in less than a week.”
Future Benefits and Outlook
With the successful implementation of this Suitable Substitute ECP, the Marine Corps can now produce the UH-1Y rescue hoist chain guard covers on an as-needed basis, with an estimated production of five to seven covers per year. This achievement is expected to pave the way for more parts to be produced through additive manufacturing, providing greater flexibility and reducing reliance on traditional supply chains.
Joe Risalek, PMA-276’s H-1 Sustainment Assistant Program Manager for Systems Engineering, praised the collaboration that made the project a success. “This was a team effort, and it is exciting to have a Get Real Get Better victory for the fleet as we continue to advance AM capability. NAVAIR exists to support the warfighter, so everything we do should be helping them.”
As the Marine Corps continues to explore the possibilities of 3D printing, the Suitable Substitute ECP process represents a significant milestone in its efforts to modernize logistics and support the fleet more efficiently.
