PATUXENT RIVER, MD — When the U.S. Coast Guard faced a critical parts shortage affecting its MH-60T helicopter fleet, they turned to the Naval Air Systems Command (NAVAIR) Additive Manufacturing (AM) Team for a swift solution. Thanks to a collaborative effort, the Coast Guard maintained operational readiness without disruption.
The issue arose in late November as Coast Guard personnel prepared to upgrade the Automatic Asset Tracking System (AATS) wiring system on their helicopters. One essential component, the AATS spacer mount, was unavailable through commercial channels. “All the parts must be in the kit before the upgrade is pushed out to the fleet,” said Lt. Cmdr. Andrew Armstrong, Surface Forces Logistics Center Industrial Operations Division branch chief and Surface Fleet Additive Manufacturing lead. Additive manufacturing was the only viable option to fabricate the part.
The Coast Guard’s AM team quickly developed a prototype and began production, only to encounter another obstacle: a shortage of Black Ultem, the polyetherimide material required for the spacer mount.
Recognizing the need for urgent support, Armstrong reached out to NAVAIR AM Program Manager Ted Gronda. Familiar with the Navy’s extensive AM capabilities and history of interagency support, Armstrong transferred the Coast Guard’s approved technical data package (TDP) to NAVAIR via the Joint Technical Data Integration (JTDI) website.
“This was an opportunity to strengthen relationships across organizations and create channels for future collaboration,” Gronda said.
A Collaborative Solution
The NAVAIR AM Team quickly assessed their resources and confirmed that their systems could meet the Coast Guard’s requirements. Engineers authorized a deviation to manufacture the parts at Fleet Readiness Center Mid-Atlantic Detachment Oceana in Virginia Beach, Virginia—the closest NAVAIR AM system to the Coast Guard’s location.
However, the necessary thermoplastic material was not available at Oceana. After making calls to multiple NAVAIR sites, the team located the Black Ultem at Patuxent River’s Polymers Research Branch.
Recognizing the urgency, a team member volunteered to personally deliver the material, driving nearly four hours from Patuxent River to Virginia Beach. Concurrently, the TDP files were uploaded, and Anna Carlson, the Additive Manufacturing Team Lead at Naval Air Warfare Center Aircraft Division Lakehurst, modified the build file to ensure compatibility with Oceana’s AM systems.
Mission Accomplished in 24 Hours
Once the material arrived, Aviation Electronics Technician Petty Officer 2nd Class Charles Oneal began production immediately. Within 24 hours, he successfully printed and delivered 15 AATS spacer mounts to Coast Guard representatives, ensuring the timely rollout of upgrade kits to the MH-60T fleet.
“This effort marked yet another extraordinarily successful example of a cross-organizational collaborative effort,” said NAVAIR AM Polymer Lead Dr. Kate Thorn. “We’re now documenting the process, so future needs can be expedited and standardized.”
Lt. Cmdr. Armstrong praised the Navy’s responsiveness, stating, “Working together, across services, we improved the readiness of a critical asset and reduced the time required to do so.”
A Model for Future Collaboration
This initiative highlights the effectiveness of interagency collaboration and the potential of additive manufacturing to address urgent operational needs. Every MH-60T helicopter in the Coast Guard fleet will now carry the additively manufactured spacer mount as part of its outfitting, a testament to the adaptability and teamwork demonstrated by both NAVAIR and the Coast Guard.
With the process now documented, both organizations are better prepared to address similar challenges in the future, further strengthening the readiness and capabilities of the nation’s military assets.
