B-1 Bomber Arrives in Wichita for Cutting-Edge “Backbone" Surgery

  • Published
  • Air Force Life Cycle Management Center Public Affairs
WICHITA, Kan. – On Sept. 9 a B-1B Lancer touched down at McConnell Air Force Base, Kansas, to undergo replacement of its Forward Intermediate Fuselage (FIF) at Wichita State University’s National Institute for Aviation Research (NIAR). 

The FIF is a critical 33-foot component located in the aircraft’s upper spine section in front of the wings and the repair is part of the BackBONE Project, which is designed to preemptively replace the FIF on B-1s once they reach the end of their durability life.

What sets this project apart is the innovative use of a digital twin. Since early 2020, NIAR has been meticulously building a digital replica of the B-1, disassembling and scanning two retired B-1s to create high-fidelity 3D models to be used in future efforts to repair and sustain B-1 aircraft.

While the digital twin wasn't initially conceived for this specific repair, it provided the essential tool set for developing this FIF repair. The team was able to model and build a replacement portion of the fuselage using the digital twin and will now proceed to install it on an operational aircraft.

Speed, Efficiency, and Cost Savings

The digital approach promises to significantly reduce the time and cost associated with this type of complex repair.

“The digital twin allows for more efficient manufacturing of parts, reduces errors, and facilitates better collaboration between engineers and technicians,” said Joe Stupic, Senior Material Leader and Division Chief of the B-1 Program Office, within the Air Force Life Cycle Management Center. “Because of our work using digital technology, I believe we can get the aircraft in and out of the [NIAR] hangar in under a year, which will be a significant cost savings for the Air Force.”

A Model for the Future

This project is not just about repairing one B-1 bomber, it’s about developing new methods for sustaining legacy aircraft.
 
“Digital is definitely taking us on a lot of twists and turns of journeys that I didn't expect,” said Dr. Melinda Laubach-Hock, NIAR Director of Sustainment. “Certainly landing an operational B-1 at a university facility seems like a crazy idea, but we've been able to prove we can execute this repair. We appreciate the trust and willingness from the Air Force B-1 Program Office, and Air Force Global Strike Command to work with us in executing the repair on this aircraft.”