3D Printed Magnesium Components: A Pathway to Strengthen Resilient Basing in Critical Air Force Platforms

Beacon Industries Inc. proposes to revolutionize aerospace component manufacturing by leveraging advanced laser 3D printing and composite coating technologies for rapid repair, reverse engineering, and deployment of critical components in battlefield conditions. This innovative approach focuses on reducing the long lead times traditionally associated with aerospace parts, ensuring mission readiness by enabling faster production and deployment of high-performance components, such as gearbox housings.What sets this solution apart is its ability to use laser-printed alloy parts, replacing outdated manufacturing processes. By implementing cutting-edge technologies like Direct Metal Laser Sintering (DMLS), we can significantly shorten design-to-production cycles. Additionally, our solution ensures the production of durable, corrosion-resistant components, enhancing reliability in critical platforms like the F-15, F-35, UH-60 Black Hawk, and MQ-9 Reaper.We achieve this through rapid reverse engineering and comprehensive testing of 3D-printed parts, ensuring compliance with military standards. This process includes detailed assessments of wear, tensile strength, fatigue, corrosion resistance, and more. Our team will update the technical data package and secure SAR (System Acceptance Review) approval to ensure the readiness of these parts for field deployment.In Phase I, Beacon Industries will scale up the reverse-engineered components and perform rigorous testing. In Phase II, we will focus on lifecycle testing, with the goal of integrating these components into the Air Force’s program of record in Phase III, thereby ensuring sustained mission capability and battlefield resilience.