KUNSAN AIR BASE, Republic of Korea -- Senior Airman Pedro Garay, Cobra Fighter Generation Squadron crew chief, recently saved his unit thousands of dollars by innovatively 3D-printing latches for Pelican cases used to transport tools and equipment.
While working in the tool crib, Garay noticed a recurring problem: many of the Pelican case latches were broken, leaving expensive equipment unsecured.
"I realized some of these latches had been broken for a while, and it was nearly impossible to replace them without buying an entirely new case," said Garay. "So I took it upon myself to fix it."
Rather than purchasing new cases, which could cost the squadron up to $17,730, Garay researched the parts online and used his personal 3D printer to create replacement parts.
This innovation not only saved the U.S. Air Force thousands of dollars, but also helped maintain the integrity of the equipment being transported.
"He saw a problem and, without being asked, looked up the schematics, printed the parts himself, and solved it,” said Maj. Adam Marthaler, Cobra FGS commander. “It's people like Garay who make a real difference by preventing small issues from becoming bigger, costly problems.”
Beyond the immediate fix, Garay’s use of 3D printing highlights the potential for broader applications of the technology.
“3D printing opens the door to so many possibilities,” said Marthaler. “Whether it's vehicle maintenance, tool repair, or office equipment, having the ability to create durable parts on-site could revolutionize how we address repairs.”
The innovation not only solved the problem of broken cases but also improved operational efficiency: Airmen no longer need to worry about lids popping open during transport, which could cause serious damage to equipment worth tens of thousands of dollars.
Garay’s forward-thinking approach sets an example for other empowered Airmen to take the initiative.
"If more Airmen took the initiative to fix small problems like Garay did, we would save time, money, and resources," said Marthaler.