The Corpus Christi Army Depot (CCAD) in Texas has begun using 3D printing technology to manufacture replacement tail fins for the UH-60 Black Hawk helicopter’s Crashworthy External Fuel System. The tail fin components frequently become damaged during loading, removal, or landing operations, rendering the aircraft inoperable when damaged. The initiative was launched in October 2025 following a shortage of components from the original equipment manufacturer.
The manufacturing process involves printing the fin in four segments using polyetherimide thermoplastic over 82 hours, followed by 16 hours of inspection per segment. The total labor time for the tail fin assembly is approximately 60 hours from start to finish. The parts must undergo rigorous inspection to verify dimensional accuracy and comply with Federal Aviation Regulation standards for flame, smoke, and toxicity requirements.
“By showcasing our processes, we want Army Aviation to know that CCAD brings solutions,” said Daniel Izcano, Composite Fabricator Supervisor. The depot maintains strict quality management systems and must secure production certificates or explicit approval from the Federal Aviation Administration to ensure airworthiness. All materials are tracked through a mandatory traceability process to certify flight readiness and safety.
The development reflects the Army’s broader shift toward composite materials in aviation. Maj. Gen. Lori L. Robinson, commanding general of the U.S. Army Aviation and Missile Command, noted that “For decades, our maintenance expertise has centered on metallic sheet metal airframes. However, the prevalence of composites demands a parallel and equally robust sustainment framework.” CCAD currently employs approximately 30 composite artisans, with Future Vertical Lift structural parts trending over 50 percent toward composite design.
Source: army.mil