Saab tests hatch 3D-printed for the exterior of a fighter jet

Saab successfully field-tested a 3D-printed hatch (white panel aft) on its Gripen fighter jet.

Saab has successfully field-tested the first part 3D-printed for the exterior of its Gripen fighter jet. The trial was conducted to test how additive manufacturing could be used during battle to repair damaged parts.

Because no 3D model of the original hatch exists, the one on the test aircraft was removed and 3D-scanned. An exact replica then was additively manufactured from PA2200, a nylon polymer. The test flight took place March 19 in the skies above Saab’s facilities in Linköping, Sweden. Afterwards, inspection showed the hatch experienced no structural changes, according to a company press release.

“The potential of this approach means that maintenance personnel in the field can get access to individually fitted spare parts, and you no longer have to resort to emergency fixes or cannibalize other broken-down aircraft for their parts,” said Håkan Stake, manager of the project team. “This also reduces the operational time lost in repairs.”

The trial marks the latest step in Saab’s commitment to AM. In 2017, it co-founded AMEXCI (Additive Manufacturing Excellence for Industry) AB, a consortium formed to advance AM technology.

The next step for the Saab team is to look for alternatives to PA2200—materials that are both flexible and can withstand the low temperatures experienced at high altitudes.

A closeup of the PA2200 hatch.