Corpus Christi Army Depot 3D Prints UH-60 Black Hawk Fuel System Components — Cuts Months Off Lead Time

The Corpus Christi Army Depot (CCAD) in Texas has begun using 3D printing to manufacture replacement tail fins for the UH-60 Black Hawk helicopter's Crashworthy External Fuel System (CEFS), marking another significant milestone in the U.S. military's adoption of additive manufacturing.

The initiative emerged after a shortage of components from the original equipment manufacturer left the depot without a reliable parts supply. According to reports from VoxelMatters, the tail fin is a component that frequently sustains damage during loading, removal, or landing operations — and even minor damage can render an aircraft inoperable as the part is deemed destroyed.

From Months to Weeks

In October 2025, CCAD's engineering branch initiated a project to produce viable replacements using additive manufacturing. Following structural analysis and technical evaluation, leadership at Redstone Arsenal determined the depot had the capability to manufacture the part in-house.

"We didn't have the files and were experiencing the furlough. But we moved forward with ordering supplies and performing software upgrades," said Justin Cook, Branch Chief for the Manufacturing Engineering Branch at CCAD.

The depot used a polyetherimide thermoplastic blend (PEI) for the 3D printed components — a material known for its excellent mechanical properties and heat resistance, making it suitable for aerospace applications.

The Growing Role of AM in Military Aviation

This development represents part of a broader trend of U.S. military facilities adopting additive manufacturing directly at army bases. The benefits extend far beyond just overcoming supply chain issues:

• Cost savings: 3D printed parts can be produced for a fraction of the cost of OEM replacements
• Lead time reduction: What previously took months can now be accomplished in weeks
• On-demand production: Depot can respond quickly to operational needs without waiting for external suppliers
• Part availability: No longer dependent on potentially scarce OEM components

CCAD has approximately 30 composite artisans on staff, and the depot is pioneering what Army officials describe as the future of composite manufacturing in Army Aviation.

The success at Corpus Christi follows similar initiatives across the military, including the recent announcement that SPEE3D cut U.S. Army replacement part time from 6 weeks to just 10 hours using cold spray additive manufacturing.

As defense departments increasingly recognize the strategic value of in-house additive manufacturing, expect more Army depots to follow CCAD's lead in producing critical components on demand.