Two weapons specialists at Luke Air Force Base have created a simple 3D-printed attachment that prevents spent ammunition casings from scattering beneath F-35A Lightning II jets, reducing the risk of costly foreign object debris damage to the aircraft’s engines.

The attachment costs less than $100 to produce, and it could solve a persistent problem faced by the US Air Force during gun system downloads, a report from ABC15 Arizona reveals.

Shielding F-35 engines from $20M in damages

Tech. Sgt. Zach Allbee and Tech. Sgt. Nik Yakel, each with about 15 years of service, designed the device known as Project ZACH, which stands for Zero Point Ammunition Cartridge Handler. The solution costs roughly $100 and addresses a known, potentially costly issue that occurs during gun system downloads.

The problem is caused by the fact that F-35A spent casings drop over six feet away from the aircraft’s loading mechanism. Typically, crews have manually positioned an ammo can to catch them. However, many of the casings would miss their target and land on the flight line, creating hazards for other aircraft.

These can cause a surprising amount of damage, according to Allbee and Yakel. A single piece of brass sucked into an engine intake, for example, can cause damage exceeding $20 million.

Allbee, who has handled 200,000 to 300,000 rounds across aircraft types, including the A-10 and F-35, told ABC15 Arizona that even experienced teams frequently lose casings. The problem is exacerbated at night when visibility is limited.

Allbee and Yakel developed their idea after observing casings scatter during a download. They proposed a guide that directs brass straight into the ammo can. With commander support and assistance from civilian engineers at Detachment 9, they advanced from an initial 3D-printed bracket and mesh netting prototype to a durable design.

The final version features a three-piece 3D-printed bracket that clamps onto the existing chute and a heavy canvas funnel. “Standard canvas material, all-weather, super durable, anti-rip, anti-tear,” Allbee said. “This is about $100.”

A streamlined approval process

The attachment hangs from the aircraft’s existing structure, and it can be reproduced using shared design files. Crucially, it does not modify the aircraft or the original loader, which will be key in facilitating approval.

The team plans to test the device further with other F-35 units at Luke before submitting the design to the Air Force’s global system. Any F-35A unit could then produce its own version at minimal cost.

Allbee and Yakel view the project as more than a fix. “When you think about a $98 fix for something as expensive as this, that’s pretty incredible,” Allbee said.

Such a low cost could yield significant savings when compared with the individual F-35 aircraft cost of up to $80 million or more, and the potential $20 million in damage the new attachment could prevent.