Designfax weekly eMagazine

Subscribe Today!

Archives

View Archives

Partners

Manufacturing Center
Product Spotlight

Modern Applications News
Metalworking Ideas For
Today's Job Shops

Tooling and Production
Strategies for large
metalworking plants

Microvanes could save Air Force $14 million annually -- for starters

Microvanes installed on a C-17 Globemaster III at Stewart Air National Guard Base. [Credit: Photo by SSgt Thaxton/Courtesy of U.S. Air Force]

 

 

The U.S. Air Force says its Operational Energy and Air Mobility Command units are entering the final phases of evaluation for microvane drag-reduction technology on the C-17 Globemaster III large transport aircraft. Developed through a collaborative effort involving the Air Force Research Laboratory (AFRL), private industry, and the Air Force Lifecycle Management Center, microvanes are expected to improve operational capabilities across the Department of the Air Force and increase the effectiveness of the USAF C-17 fleet.

The C-17 microvanes are 3D-printed devices measuring approximately 4 x 16 in., resembling a thin blade. Using strong adhesive bonding, a dozen of these devices are attached to the rear of the C-17's exterior. The Air Force says C-17s equipped with microvanes experience a 1% reduction in drag (and fuel consumption) compared to their unmodified counterparts.

In early testing, the microvanes were made of nylon and filled with 3D-printed glass beads. These prototypes were 2.4 in. tall and 16 in. long. Twelve microvanes, six on each side at the rear of a C-17 fuselage, were installed using a Mylar template.

"Microvanes essentially clean up the airflow in the region of the cargo door by re-energizing the air with small vortices that delay separation, smooth the flow, and reduce drag," said Capt. Randall Hodkin, AFRL Advanced Power Technology Office aviation working group lead on the 2018 testing efforts. "Historically, cargo aircraft have airflow issues in the aft region of the airframe due to the required upsweep of the fuselage to integrate a cargo ramp."

A C-17 Globemaster III with microvanes successfully installed waits on the flight line at Stewart Air National Guard Base. [Credit: Photo by SSgt Thaxton/Courtesy of U.S. Air Force]

 

 

"With support from Dover AFB, we were able to validate that the tooling developed as part of the AFRL program can position C-17 microvanes in the correct location to achieve the expected one percent fuel savings," said Hodkin.

Early real-world C-17 microvane flight testing was conducted at Edwards AFB, California, and Dover Air Force Base, Delaware, between 2016 and 2018. This initial flight test program was able to validate that microvanes reduce drag by one percent when in cruise. In addition, the Edwards AFB flight tests also included several test scenarios to validate that microvanes do not affect the critical C-17 airdrop mission capability.

In an effort to reduce drag and fuel consumption, the 736th Aircraft Maintenance Squadron personnel installed 12 microvanes, six on each side, at the rear of a C-17 Globemaster III fuselage, Sept. 6, 2017, at Dover Air Force Base. The 3D-printed, early-prototype glass-bead-filled nylon microvanes were 2.4 in. tall and 16 in. long. [Credit: U.S. Air Force photo by Roland Balik/Courtesy of U.S. Air Force]

 

 

 

 

Testing has continued through the years. The microvanes are now taller. According to an Air & Space Forces Magazine 2022 article, "Microvanes were originally developed by Lockheed Martin in collaboration with the Air Force" and, in their present iteration, microvanes "are 3D-printed from DuraForm GF/DuraForm ProX GF composite material." The article also stated the microvane program "has cost approximately $5 million so far to develop" and that Metro Aerospace "holds the license to Lockheed Martin's patent on the technology" which will be used to develop microvanes for other military aircraft.

During flight, microvanes enhance fuel efficiency and extend the mission range by reducing aerodynamic drag caused by the upswept design of the cargo door section. When installed across the entire USAF C-17 fleet, including Air National Guard and Air Force Reserve aircraft, microvanes are a low-cost, innovative, force-multiplying capability that improve mobility support to the joint force in high-demand mission requirements. The financial savings, along with increased operational capability, has garnered strong interest from partner nations, including Canada and the United Kingdom, to add the modification to their C-17 fleets.

This transformative technology is projected to yield a return of investment within seven months from efficiencies gained through fuel cost reductions, saving the Air Force over $14 million annually, while simultaneously improving the aircraft's capabilities.

"Every gallon of fuel saved strengthens our readiness and operational effectiveness," said Roberto Guerrero, Deputy Assistant Secretary of the Air Force for Operational Energy, Safety, and Occupational Health. "By adding modern technology like microvanes to our legacy aircraft, we're saving millions in fuel costs and building capability critical for maintaining our competitive edge in the era of Great Power Competition."

This initiative has been the subject of rigorous research and evaluation over several years. Microvane technology has also earned approval by the U.S. Army for use in paratrooper airdrop. In October 2023, the Department of the Air Force initiated the final phase of flight testing, which included air refueling and assault strip operations. Notably, the aircraft used in this testing retained the microvanes and became the first permanent installation of the technology in the C-17 fleet. That aircraft is currently assigned to Stewart Air National Guard Base.

"The Microvanes initiative combines Stewart's efforts to modernize Mobility Air Forces with innovative mission-ready Airmen," said Lt. Col Eric Durkins, Commander, 105th Aircraft Maintenance Squadron at Stewart Air National Guard Base. "We paired up with Memphis ANGB, which increased process knowledge across both wings. Our maintainers, working side by side with an engineering team from the start of this project, helped develop the installation procedures for the C-17 enterprise. The aircraft has supported our worldwide missions now for over a year without an issue, to include an AOR deployment."

Currently, six aircraft are modified for the Logistics Service Assessment (LSA), which is the final step before fleetwide fielding. The six-month LSA will begin after the final two aircraft are modified at Charleston AFB this month, with the intent to expand microvane use across the entire C-17 enterprise.

"This collaboration highlights how partnerships drive forward our mission objectives," added Guerrero. "It's about ensuring that we remain agile and capable in a rapidly evolving global environment. What's more, through recent legislation, we can use the savings realized by this technology to fund other initiatives that increase combat capability."

As the global landscape rapidly evolves, the ability to extend mission ranges without overburdening fuel supply chains directly translates to enhanced mobility, enabling the Air Force to deploy and sustain the Joint Force more effectively in geographically dispersed and resource-constrained theaters. Microvane technology, along with other projects supported by DAF Operational Energy, marks a significant step forward in optimizing legacy aircraft and ensuring the U.S. Air Force remains at the forefront of global airpower.

Sources: U.S. Air Force, Air & Space Forces Magazine

Published February 2025

Rate this article