Oklahoma University and ORNL Collaborate

The University of Oklahoma (OU), Norman, Oklahoma, and Oak Ridge National Laboratory (ORNL), Oak Ridge, Tennessee, in collaboration with the Air Force Sustainment Center, the Air Force Research Laboratory (AFRL), and the Oklahoma City Air Logistics Complex, are launching Phase II of a transformative additive manufacturing initiative aimed at modernizing how the military sustains legacy aircraft. OU has been awarded $8.8 million to support the next stage of the program.

The effort addresses a pressing challenge in military aviation: many aircraft remain in service for 60 years or more, while replacement parts become increasingly scarce. Phase II will focus on streamlining the certification and airworthiness approval process for 3D‑printed components. Instead of certifying each material, geometry, and machine individually—a costly and time-intensive approach—the team will implement a data-driven framework that digitally tracks the entire manufacturing process. This integrated system will enable parts to be produced across multiple platforms while meeting strict military safety standards.

Building on Phase I’s work in laser powder bed fusion for replacement parts, Phase II expands into component repair, artificial intelligence-driven quality assurance, and in situ process monitoring. Research will be conducted through OU’s Sooner Advanced Manufacturing Laboratory, strengthening its strategic partnership with ORNL and leveraging national laboratory tools such as advanced manufacturing software platforms.

By establishing standardized qualification pathways for additive manufacturing, the program aims to reduce production timelines, enhance fleet readiness, and create a repeatable certification model for the Air Force sustainment enterprise. The collaboration also reinforces Oklahoma’s growing aerospace and defense ecosystem while training the next generation of engineers in mission-critical manufacturing technologies.