Features

Innovation from the ground up

Photos by Master Sgt. Nicholas Filip
December 11, 2020
U.S. Air Force Airman 1st Class Trevor Zucker, 1st Combat Communications Squadron radio frequency transmissions technician, manipulates a 3D model of a quad-band large aperture antenna mounting bracket he created using a computer-aided design program on his laptop Nov. 19, on Ramstein Air Base. Creating a 3D model was the 1st step in preparing a printable version of the bracket that could then be installed on the Q-LAA. Zucker created the replacement part because of the challenges in obtaining replacement brackets, preventing the satellite communications system from becoming non-mission capable.

 

U.S. Air Force Brig. Gen. Christopher Ireland, U.S. Air Forces Europe–Air Forces Africa Chief of Staff, presents his pre-sanitized coin to U.S. Air Force Airman 1st Class Trevor Zucker, 1st Combat Communications Squadron radio frequency transmissions technician, following the inspection of a 3D-printed mounting bracket created by Zucker and installed on a quad-band large aperture antenna system Nov. 18, on Ramstein Air Base. “This is exactly the kind of innovative problem-solving we hope to see from today’s Airmen,” said Ireland. “Airman 1st Class Zucker preserved the mission capability of a satellite communication system because of his idea, his drive to put it into action, and his leadership’s support.

 

U.S. Air Force Airman 1st Class Trevor Zucker, 1st Combat Communications Squadron radio frequency transmissions technician, prepares a 3D printer system by routing poly lactic acid filament through a filament feeder Nov. 19, on Ramstein Air Base. He demonstrated the 3D printer’s ability to produce some components that could be used as replacement parts in military systems. Zucker used the printer to create a mounting bracket for the quad-band large aperture antenna system because of the challenges in obtaining replacement brackets, preventing the satellite communications system from becoming non-mission capable.

 

A 3D printer forms a plastic mock-up of a mounting bracket used on the quad-band large aperture antenna system Nov. 19, on Ramstein Air Base. U.S. Air Force Airman 1st Class Trevor Zucker, 1st Combat Communications Squadron radio frequency transmissions technician, used his own time to create a 3D model of the bracket using a computer-assisted design program, and then used his personal 3D printer to produce a nylon filament proof-of-concept. Zucker created the part because of the challenges in obtaining replacement brackets, preventing the satellite communications system from becoming non-mission capable.

 

U.S. Air Force Airman 1st Class Trevor Zucker, 1st Combat Communications Squadron radio frequency transmissions technician, demonstrates the similarities between the original and a 3D-printed version of a mounting bracket used in the quad-band large aperture antenna system Nov. 24, on Ramstein Air Base. The safety specifications of the 3D version are currently being verified before being placed into service on the Q-LAA. Zucker created the part because of the challenges in obtaining replacement brackets, preventing the satellite communications system from becoming non-mission capable.

 

U.S. Air Force Airman 1st Class Trevor Zucker, 1st Combat Communications Squadron radio frequency transmissions technician, installs a 3D-printed mounting bracket onto a quad-band large aperture antenna system Nov. 24, on Ramstein Air Base. Zucker created the part because of the challenges in obtaining replacement brackets. A normal replacement can take as long as six months to arrive, which could potentially place the satellite communications system into a non-mission capable status.

 

An original mounting bracket used on the quad-band large aperture antenna system sits atop one of the cases that stores the satellite communications system when is disassembled Nov. 24, on Ramstein Air Base. U.S. Air Force Airman 1st Class Trevor Zucker, 1st Combat Communications Squadron radio frequency transmissions technician, 3D-printed a nylon bracket that can withstand temperatures of up to 200 degrees Fahrenheit and up to 4,000 pounds of pressure, making it a suitable substitution. Zucker created the part because of the challenges in obtaining replacement brackets, preventing the satellite communications system from becoming non-mission capable.

 

U.S. Air Force Airman 1st Class Trevor Zucker, 1st Combat Communications Squadron radio frequency transmissions technician, climbs up a quad-band large aperture antenna while finishing assembly of the satellite communications system Nov. 24, on Ramstein Air Base. Zucker used a 3D printer to create a mounting bracket out of nylon, reducing the risk of corrosion and deformation, which can happen over time to the original part. Zucker created the part because of the challenges in obtaining replacement brackets, preventing the satellite communications system from becoming non-mission capable.
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