Yokota Air Base, Japan — Tech. Sgt. Tylar Cravens is pioneering a project that may transform how the Air Force trains aircraft maintainers. Scheduled to pitch his initiative to Pentagon leaders, Cravens, an engine mechanic specializing in the C-130J Super Hercules with the 373rd Training Squadron, Detachment 15, has developed "Star Forge." This innovative project employs advanced 3D printing technology to create full-scale composite training engine models, which would allow aircraft maintainers to practice using realistic equipment without needing to take actual aircraft out of service.
Cravens emphasized the importance of demonstrating the Air Force’s capacity for advanced manufacturing, saying, “It’s something that could potentially revolutionize the way we do hands-on training.” His initiative can bridge a significant gap in maintenance training by providing safer, cost-effective practice alternatives. Traditional training methods rely heavily on operational equipment, limiting opportunities and increasing expenses. Each of Cravens’ 3D-printed replicas costs just $12 to produce, thereby offering a more efficient training route.
"I thought, ‘Why are we using the same parts and the same equipment that we are going to rely on for tomorrow’s mission?’” he questioned, advocating for the need to innovate in training practices. Cravens, a 3D printing enthusiast, began working on this concept three years ago through YokoWerx, the innovation cell at Yokota. With a supportive team of Airmen from Japan, the U.S., and Europe, he refined his idea into a comprehensive training system.
His expertise in additive advanced manufacturing has made him a key figure in YokoWerx, as noted by Tech. Sgt. Michael Feagin, project manager for the innovation cell. Cravens is one of six airmen competing in the Air Force Spark Tank finals, modeled after the television show "Shark Tank." Here, airmen propose solutions to various operational issues, with the finalists presenting their concepts to senior Air Force leaders.
The upcoming competition winner, which may be impacted by the current government shutdown, will receive a trophy, the opportunity to garner leadership support for their concept, and international exposure. Col. Richard McElhaney, commander of the 374th Airlift Wing, expressed confidence in Cravens and his team, highlighting the innovative spirit present at Yokota.
Cravens shared his drive is fueled by a desire to make a lasting impact in the maintainer community: “I have poured out my heart and soul to this project. We want to leave our Airmen fit to fight and ensure they possess the best training possible.”