A Cozy Mk IV light aircraft crashed during its landing approach at Gloucestershire Airport after a critical 3D-printed part softened and failed, according to a report from the Air Accidents Investigation Branch (AAIB).
The aircraft was completing an otherwise uneventful local flight when the pilot advanced the throttle and experienced a sudden, complete loss of engine power. Despite the setback, the pilot skillfully navigated the plane over a nearby road and bushes but ultimately landed short, striking the instrument landing system (ILS) localiser before coming to a halt beside the structure.
Though the pilot sustained only minor injuries, the aircraft was destroyed, and the ILS installation suffered damage.
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Investigation revealed that the failure originated from a plastic air induction elbow connected to the fuel controller. This component collapsed, severely restricting airflow into the engine and causing the power loss. Notably, the elbow was a 3D-printed part acquired at a U.S. airshow and installed as part of modifications to the fuel system.
The AAIB found that the plastic material used in the induction elbow softened when exposed to heat from the engine, leading to its collapse. The aircraft owner had not identified the 3D-printed part as a hazard, mistakenly believing the filament’s temperature resistance was comparable to the laminated epoxy specified in the original aircraft build manual.
The investigation concluded that the air induction elbow was made from an inappropriate material for its application. The AAIB has indicated that enhanced safety measures will be introduced regarding the use of 3D-printed parts in aircraft.
In response, the Light Aircraft Association (LAA) announced plans to issue a ‘LAA Alert’ to all LAA Inspectors, warning against the use of unsuitable 3D-printed components in aircraft construction and maintenance.