“Once I created the prototype, I brought it to my section and tested it out,” Helzer said. Helzer, using his skill and knowledge with 3D printing, created a prototype called the “Boom Cover Tool.” The tool was manufactured with Helzer’s 3D printer and resembles a butterfly net on the end of a retractable pole with a hoop mechanism that tightens and loosens the net covering on the opposite end.
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“He spent a lot of his free time, outside of work, designing the boom cover tool,” Jakubowski said. Steven Jakubowski said Helzer is always looking for ways to innovate and constantly asking questions to gain further knowledge. “I then came up with a prototype for a tool that could make the process much smoother.” “One of the maintenance crew chiefs reached out because he knew I enjoy 3D printing and design and believed I could come up with a solution for the boom cover,” Helzer said. The current conventional method hinders daily operations, whereas the innovative solution Helzer created is easier, takes less time and lessens the impact on the flow of operations. “Removing the cover the conventional way involves calling the Aerospace Ground Equipment backshop for an aircraft stand and requires two Airmen and a substantial amount of time.” “I noticed as soon as I got to Mildenhall that removing and installing the boom cover was tedious and time consuming,” said Airman 1st Class Jacob Helzer, 100th MXS hydraulics maintenance journeyman.
Air Force 40,000 man-hours and approximately $1 million per year. One 100th Maintenance Squadron Airman has invented a new boom cover tool that has the potential to save the U.S.
Thousands of hours are spent each year removing and installing a boom cover on a KC-135 Stratotanker aircraft – hours that could be used elsewhere. 100th Air Refueling Wing Public Affairs.
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