RAF Wittering News

New Journey In RAF Engineering Begins With Wittering Squadron

A new journey in RAF Engineering began with the creation of the Hilda B Hewlett Centre for Innovation by No 71 Inspection & Repair (IR) Squadron.

From left to right: Helen Close, Heritage Officer for the Women’s Engineering Society and Flying Officer Jemima Burgess of No 71 (IR) Squadron
From left to right: Helen Close, Heritage Officer for the Women’s Engineering Society and Flying Officer Jemima Burgess of No 71 (IR) Squadron
Image By: AS1 Maryanne Williams

Equipped with world-leading 3D printing and scanning equipment, the opening of the new centre marks the Royal Air Force’s first steps into advanced component manufacturing. 3D printing, properly known as additive manufacturing, is the layer-by-layer construction of a three-dimensional object from a digital 3D model.

From left to right: Group Captain Craig Watson and Squadron Leader Allen Auchterlonie on front of the Wayland Additive Calibur3 3D printer
From left to right: Group Captain Craig Watson and Squadron Leader Allen Auchterlonie on front of the Wayland Additive Calibur3 3D printer
Image By: AS1 Maryanne Williams

Additive manufacturing is a new ability for No 71 (IR) Squadron and could provide a breakthrough in the RAF’s ability to design and produce its own aircraft spares on demand. The project was begun by Squadron Leader Phil Hayward in 2020, then officer commanding of No 71 (IR) Squadron.

A Wayland Additive Calibur3 3D printer is at the cutting edge in additive manufacturing technology and the RAF will be the first customer in the world to operate one. There is also a Nikon HTX 540 CT scanner, which can examine objects in minute detail. Renishaw’s RenAM 500 metal printer and a Stratasys Fortus 450 polymer printer provide reliable 3D printing capabilities which perfectly complement the Wayland and Nikon machines.

The team from 71(IR) Squadron in the special anti-static workwear required for additive manufacture
The team from 71(IR) Squadron in the special anti-static workwear required for additive manufacture
Image By: AS1 Kimberley Waterson

Squadron Leader Allen Auchterlonie is Officer Commanding No 71 (IR) Squadron. He said: “One day the Royal Air Force  could  manufacture custom-built structural aircraft components for rapid aircraft repairs. This technology has endless possibilities in supporting and delivering air power  and the opening of this facility is a landmark in this exciting journey.”

71 (IR) Squadron is part of the RAF A4 Force. Its principal roles are to repair damaged structure on UK fixed-wing military aircraft and provide specialist inspection capabilities to RAF aircraft wherever they are deployed. The Squadron also has its own designers, who devise repair solutions in circumstances where conventional fixes may not be effective or available.

Some examples of 3D printed components
Some examples of 3D printed components
Image By: AS1 Kimberley Waterson

Working in metal or polymer, the new equipment can reproduce aircraft components with microscopic accuracy and precision.  Before any manufactured component can be fitted to an aircraft, however, months of rigorous testing lies ahead with every imaginable aspect of the additive manufacture process examined in scientific detail.

Some examples of 3D printed components
Some examples of 3D printed components
Image By: AS1 Maryanne Williams

The centre was formally opened by Air Chief Marshal Sir Mike Wigston, Chief of the Air Staff. Sir Mike noted that ‘success has many parents’ and praised the combined efforts of 71 (IR) Squadron, the RAF Rapid Capabilities Office and Project ASTRA in bringing ‘Project Warhol’ as it is known, to life.

Air Chief Marshal Sir Mike Wigstone at the opening of the Hilda B Hewlett Centre for Innovation
Air Chief Marshal Sir Mike Wigston at the opening of the Hilda B Hewlett Centre for Innovation
Image By: AS1 Kimberley Waterson

Helen Close, Heritage Officer for the Women’s Engineering Society, spoke about the life of Hilda B. Hewlett. The first British woman to hold a pilot’s licence, she led the development of aircraft technologies as a manufacturer of military planes in World War 1. Squadron Leader Auchterlonie said: “Hilda B Hewlett was unquestionably a pioneering visionary, who embodied courage and a spirit of innovation. It is because of this, that we have proudly named our new facility after her.”

Hilda B. Hewlett circa 1911
Hilda B. Hewlett circa 1911
Image By: Unknown Author

The Hilda B Hewlett Centre for Innovation has a modern feel. No 71 (IR) Squadron’s engineers will work closely with its delivery partners from Wayland Additive, Nikon, Renishaw and Stratasys to understand how 3D printing technology can be developed into a functioning military capability.

Group Captain Nick Huntley commands the A4 Force Elements. He said: “Additive manufacturing offers us enormous potential to repair and modify our aircraft quicker than ever before. Introducing any new capability into the RAF is a serious undertaking and the team at 71 Squadron have gone about this with professionalism and almost obsessive diligence. This is a genuine milestone; a real achievement and I am proud that this project has been led by the A4 Force.”

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