The KC-135 Fan Duct Actuator Housing Project

When the Air Force required KC-135 Fan Duct Actuator Housings—an out-of-production part originally manufactured in the 1970s—Elevate Systems stepped in to provide a cutting-edge solution. Known for their multidisciplinary engineering expertise, Elevate Systems tackled the challenge of reverse engineering and additive manufacturing with precision and innovation.

The original housings, which had no available data and were critical to the proper operation of the fan duct actuators, presented a significant obstacle to aircraft availability. Elevate Systems approached the task methodically, beginning with a detailed reverse engineering process. Using advanced metrology, the team ensured dimensional accuracy, creating precise 3D models of the original part. These models were utilized to produce polymer prototypes, which were validated for accurate measurements.

Following this validation, the process advanced to additive manufacturing (AM). Starting with a nylon prototype, Elevate Systems transitioned to aluminum metal additive manufacturing to produce the final housing. The AM process, which eliminates the need for expensive tooling, saved the Air Force tens of thousands of dollars. After machining to remove support structures, the final part not only matched but exceeded the strength and quality of the original cast and machined component.

Elevate Systems delivered more than just the part itself. Their end-to-end service included a comprehensive package of resources: 2D and 3D files, native CAD files, and all necessary testing data to achieve airworthiness certification. These deliverables ensured that the Air Force was equipped with everything needed for testing and operational readiness of the KC-135 platform.

The KC-135 Fan Duct Actuator Housing project exemplifies Elevate Systems' ability to blend traditional manufacturing techniques with modern innovations like additive manufacturing. Their meticulous approach and commitment to providing a complete solution allowed the Air Force to restore critical components, maintain aircraft readiness, and achieve significant cost savings.