Tech. Sgt. Tylar Cravens' Star Forge project uses advanced 3D printing to create full-scale composite training engine models, allowing maintainers to practice on realistic equipment without taking aircraft out of service. (Juan King/Stars and Stripes)
YOKOTA AIR BASE, Japan — Tech. Sgt. Tylar Cravens believes he has an idea that could change the way the Air Force trains aircraft maintainers, and he’ll soon pitch it to top leaders at the Pentagon.
Cravens, a C-130J Super Hercules engine mechanic with the 373rd Training Squadron, Detachment 15, is one of six airmen selected worldwide to compete in the Air Force Spark Tank finals on Oct. 22.
His project, Star Forge, uses advanced 3D printing to create full-scale composite training engine models, allowing maintainers to practice on realistic equipment without taking aircraft out of service.
Tech. Sgt. Tylar Cravens, a C-130J Super Hercules engine mechanic with the 373rd Training Squadron, Detachment 15, is one of six airmen selected worldwide to compete in the Air Force Spark Tank finals on Oct. 22, 2025. (Juan King/Stars and Stripes)
“I am trying to prove to the Air Force that we have this advanced manufacturing capability,” he told Stars and Stripes during a recent interview at Yokota, home of U.S. Forces Japan, 5th Air Force and the 374th Airlift Wing in western Tokyo. “It’s something that could potentially revolutionize the way we do hands-on training.”
Star Forge aims to fill a critical gap in maintenance instruction. Aircraft maintainers often rely on operational equipment, which can limit training opportunities and drive up costs. Cravens’ 3D-printed replicas of engine parts, which cost only $12 to produce, would give maintainers a safer, lower-cost way to build their skills before working on real aircraft.
“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 said.
Tech. Sgt. Tylar Cravens says his 3D-printed engine parts replicas, such as the one pictured at right, would give maintainers a safer, lower-cost way to build their skills before working on real aircraft. (Tylar Cravens)
Cravens, a 3D printing hobbyist, developed the idea three years ago through YokoWerx, the base’s innovation cell. Using his own 3D printer, he produced replica parts to demonstrate the concept. His team — made up of airmen in Japan, the United States and Europe — helped refine it into a full training system.
Cravens has become YokoWerx’s “expert as far as additive advanced manufacturing goes,” the innovation cell’s project manager, Tech. Sgt. Michael Feagin, recently told Stars and Stripes.
Spark Tank, modeled after the TV show “Shark Tank,” gives airmen a chance to pitch solutions to operational challenges. Ideas are submitted through the Airmen Powered by Innovation portal, with finalists advancing to a live pitch event before senior Air Force leaders.
Tech. Sgt. Tylar Cravens' Star Forge project uses advanced 3D printing to create full-scale composite training engine models, allowing maintainers to practice on realistic equipment without taking aircraft out of service. (Tylar Cravens)
The winner of the competition, which Cravens said may be postponed due to the ongoing government shutdown, receives a trophy, support for their ideas from Air Force leadership and global exposure.
“Yokota runs on innovative, empowered, problem-solving Airmen who take intent and turn it into action,” 374th Airlift Wing commander Col. Richard McElhaney said Thursday in an email to Stars and Stripes. “I wish Team Yokota the best of luck and look forward to the competition results and continued wins from our Futures Office.”
Cravens said his motivation comes from wanting to leave a lasting impact on the maintainer community.
“I have poured out my heart and soul to this project,” he said. “We want to leave our airmen fit to fight and leave them with the best training possible.”
