Joe Owings programs the Hurco 5-axis milling machine to manufacture mounting fixtures, each with its own angle of attack 
for hypersonic wind tunnel testing. (U.S. Air Force photo by Jack Gardner)

Innovation at AFIT’s Graduate School of Engineering and Management, part of Air University, just got a major boost. The Model Fabrication Shop recently acquired new state-of-the-art machinery, which will allow faculty and student researchers to bring more complex and dynamic projects to life.

From computer-aided design and 3D printing, to welding and woodworking, the model shop is the Graduate School’s go-to manufacturing facility – assisting faculty and students to design, modify, build, repair, and create.

New Equipment Specifications
The new 5-axis milling machine (Hurco VMX60SRTi) is a high-performance machining center designed for complex toolpaths and multi-sided prototypes. It uses a wide range of conventional cutting tools including end mills, drills, reamers, taps, thread mills, and boring heads to precisely remove material under fully automated computer control. The result is a finished component produced to exact specifications.

The Sodick ALN600G with the WS4 4th-axis rotary is a high-precision wire EDM system designed for complex shapes, tight tolerances, and fine details. Using a continuously fed electrically charged wire, it erodes material with exceptional accuracy, producing geometries that conventional machining cannot achieve. As a result, it is well-suited for Air Force research and development work, experimental hardware, precision prototypes, and complex components supporting advanced aerospace and defense technologies.

“Investing in high-end manufacturing equipment equates to shorter lead times on projects, superior prototypes, and better quality control, leading to high-value testing data for AFIT research,” said Christopher Harkless, AFIT model maker.

Bailey Bustamante operates Sodick wire EDM to post process combustion test components that were additively manufactured from Inconel.
(U.S. Air Force photo by Jack Gardner)

Dan Ryan creates a 4-axis wire EDM toolpath to alter radar calibration targets. (U.S. Air Force photo by Jack Gardner)

Expanded Project Capabilities
Model shop team members are excited to provide expanded project capabilities in support of the cutting-edge research conducted by Graduate School faculty and students.

A few examples of potential manufacturing projects include: precise aerodynamic profiles for hypersonic vehicle research and development, modular satellite systems and components for space applications, advanced antenna designs for remote sensing, fabrication of models for flight experimentation and validation, combustion rig manufacturing, and production of stable platforms for advanced optical and laser-based experimentation. 

Contact Information
The Model Fabrication Shop provides machining, fabrication, repair, inspection, welding, woodworking, laser cutting, 3D printing, computer aided design, and more.

AFIT faculty, students and staff are encouraged to reach out to the model shop at modelshop@afit.edu to schedule an appointment to discuss upcoming research project needs.

AFIT Model Fabrication Shop team members shown above. Front row from left: Mr. Joseph Owings, model maker, and Mr. Sean Wear,
mechanical designer. Back row from left: Mr. Christopher Harkless, Mr. Bailey Bustamante and Mr. Daniel Ryan, model makers.
Mr. Brian Crabtree, supervisor, not pictured. (U.S. Air Force photo by Jack Gardner)

About AFIT

AFIT’s Graduate School of Engineering and Management (GSEM) provides in-residence and distance learning graduate degrees and certificates in engineering, applied science, mathematics and management. GSEM provides its students with several significant advantages: a more personalized educational experience, academic programs with a defense-related focus, and research on high-priority defense problems.  

AFIT is located at Wright-Patterson AFB, Ohio. AFIT’s mission is to educate defense professionals to innovatively accomplish the deterrence and warfighting missions of the USAF and USSF. AFIT’s vision is to lead defense-focused education, research and consultation to accelerate military superiority across all domains and is accomplished through operationally relevant advanced academic education, research, and professional continuing education. For more information, please visit the AFIT webpage https://www.afit.edu/ or contact GSEM outreach at AFIT.EN.Outreach@us.af.mil.