Personnel from the 305th Maintenance Squadron have successfully fabricated a structural component for the KC-46A Pegasus tanker, enabling the aircraft to meet operational requirements after a shortage of manufacturer-supplied parts.
The KC-46A Pegasus is a modern U.S. Air Force tanker aircraft that conducts aerial refueling, cargo transport, and aeromedical evacuation missions. It was designed with a glass cockpit, allowing for advanced approaches and operations in various conditions.
The KC-46A features both a rigid boom and a hose-and-drogue system for refueling different types of aircraft, and it completed its first nonstop circumnavigation of the globe in 2024.
The effort focused on the Aileron C-channel, a component integral to the aircraft’s wing that provides stability in flight. According to U.S. Air Force Tech. Sgt. Dontie Custis, the noncommissioned officer in charge of Aircraft Metals Technology for the 305th MXS, a failure of this part could lead to significant structural damage from stress and vibrations during operation.
Ordinarily, maintenance crews would obtain official blueprints from the aircraft’s manufacturer, Boeing, to fabricate replacement parts. However, in this instance, the necessary technical data was unavailable due to mission requirements, necessitating an alternative approach.
Faced with the potential grounding of affected aircraft, metals technology personnel within the squadron took measured steps to address the problem. They reverse-engineered the component, creating their own detailed blueprints and 3-dimensional models. This prototype data was then submitted to engineers from both Boeing and the Air Force for review and approval. Following minor adjustments, the squadron began manufacturing the part.
The successful fabrication prevented operational delays. Staff Sgt. Cyrus Bartony, a craftsman with the squadron, confirmed that aircraft found with damaged C-channels during inspection would be grounded until repaired. The in-house solution allowed the maintenance group to clear those aircraft for flight.
Tech. Sgt. Custis emphasized the necessity of the action, stating that without the ability to make the repairs, a recent deployment cycle could not have been successfully completed. He noted the significant, unquantified costs that would have been associated with acquiring the information rights or pre-made parts were avoided.
The 305th MXS has since disseminated its newfound capability, providing training to personnel from Pease Air National Guard Base, New Hampshire. Requests for manufacturing assistance have also been received from McConnell Air Force Base, Kansas, and Travis AFB, California.
The initiative has provided the squadron with the proven capacity to manufacture the C-channels and the confidence to address similar parts shortages in the future, ensuring the KC-46A fleet remains mission-ready.