Indian Air Force Turns to 3D Printing for Rubber Aircraft Parts

The Indian Air Force has started using 3D printing to manufacture rubber parts for Russian-origin aircraft and helicopters, a move driven by delays in spare part supplies. Instead of waiting weeks or months for components to arrive from abroad, maintenance depots can now design and print replacement parts in-house within days.

The initiative is being led by the Base Repair Depots, which handle repair, overhaul, and upgrades of aircraft and equipment. The effort began with non-critical components and is now expanding to critical parts. The printed parts are made from flexible thermoplastic elastomers and soft photopolymer resins, materials that do not require special molds. A digital design file can be reused indefinitely, and parts can be produced in small batches or as single units on demand.

Each printed part goes through testing for flexibility, sealing performance, and durability before it is installed on an aircraft. The shift to 3D printing fits into India's broader self-reliance push in defense manufacturing. The same technology is already being used for plastic and metal parts at various depots.

The Air Force is not positioning 3D printing as a replacement for all supply chains. It is a tool for closing gaps where foreign spares are unavailable or delayed. In that role, it is already making more aircraft available for operations.