Wall Colmonoy Wins USAF Contract to Remanufacture F-16 Heat Exchangers

Keeping Older F-16s Flying

Wall Colmonoy Oklahoma City has won a multi-year, multi-million-dollar contract from the United States Air Force to remanufacture F-16 secondary heat exchangers. The work applies to two specific part numbers and covers overhaul, re-coring, and return to service.

The Oklahoma City facility has built heat exchangers for military and commercial aircraft for decades. Its experience with high-temperature furnace brazing lets the company repair components rather than replace them, which cuts costs and keeps aging fleets operational.

The contract extends beyond the F-16. Wall Colmonoy Oklahoma City manufactures Nicrocraft exhaust systems for general aviation aircraft, holding FAA Parts Manufacturer Approval for Beechcraft, Cessna, Cirrus, Aeronca, and Piper models. It also builds original equipment exhaust systems for Robinson helicopters.

The Additive Manufacturing Context

While Wall Colmonoy's contract relies on traditional brazing and machining, additive manufacturing is gaining traction across U.S. defense sustainment programs. The Navy's RESTORE laboratory used 3D scanning and 3D printing to repair legacy combat equipment after rainwater damaged an AN/TRC-194 antenna drive. Original tooling for that 1988 system was gone, so engineers scanned the part and printed a replacement.

More recent Navy programs have expanded that approach from one-off repairs to a distributed sustainment system. The Additive Manufacturing Center of Excellence has delivered over 300 3D printed components for aging naval vessels, including reverse-engineered parts for Ohio-class submarines. Another project replaced a USS Halsey helicopter hangar-door bracket in just over two weeks after conventional procurement produced a 40-week lead time.

Wall Colmonoy's contract is a reminder that legacy sustainment still depends on traditional manufacturing skills. But the examples above show how quickly additive manufacturing is becoming another tool for keeping old equipment flying when spares disappear.