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Custom Design & Production

Faes wraps F-16 vertical tail on site

Faes developed and assembled a custom-made wooden crate on site for the safe transport of the vertical tail of an F-16 from Volkel Air Base. Thanks to 3D scanning technology and close cooperation with the Ministry of Defence, a complex packaging solution was realised that fits in with the phasing out of the F-16 and the transition to the F-35.

Michel Prins

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5 minutes reading time

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10 October 2024

Summary of this article

Packaging large, vulnerable defence components is often regarded as an operational logistics task, while in reality it combines engineering, risk management and operational planning. For the transport of an F-16 vertical tail, Faes developed a custom wooden crate that was constructed around the component at Volkel Air Base. The key challenge lay in its exceptional dimensions, fragile structure and the absence of technical drawings due to the classified nature of the component.

When packaging is designed remotely and solely on the basis of standard specifications, the risk of dimensional inaccuracies, inadequate securing and delays increases. Faes therefore inspected the component on site and measured it accurately using 3D scanning technology. Based on this data, the vulnerable areas were identified, the packaging design was developed and the individual components were prefabricated. Final assembly took place around the vertical tail, ensuring that the crate fitted precisely and was ready for transport on schedule.

The project demonstrates that complex packaging challenges become easier to manage when digital measurement technology, engineering and execution are organised as a single process. By coordinating with the Dutch Ministry of Defence at an early stage and producing the packaging partly in advance and partly on site, safety, confidentiality and planning could be successfully combined. In this way, custom packaging becomes an essential part of the controlled phase-out and international relocation of F-16 equipment, rather than a separate activity at the end of the process.

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A custom packaging solution at Volkel Air Base.

Faes provided an F-16 vertical tail with custom packaging at Volkel Air Base so that it can be shipped abroad. The aircraft may still make 300 flying hours before it has to be officially disposed of, but this will no longer take place in the Netherlands. By sending the F-16 aircraft in parts, it can be assembled and "used up" at its final destination. An impressive project, if only considering the enormous dimensions of the tail (3465 x 450 x 2750 mm). On site, we built the crate around the F-16 tail, with additional fixation where necessary for the vulnerable areas.

Medewerkers van Faes plaatsen deksel op houten maatwerk kist voor veilige verpakking van een F16 vleugel, klaar voor transport.

Medewerkers van Faes begeleiden een F16 vleugel naar een houten maatwerk kist voor veilig transport, met ondersteuning van militaire partners.

Faes team werkt aan een houten maatwerk kist voor het veilig transporteren van een F16 vleugel, met meerdere teamleden en apparatuur in de werkplaats.

Faes medewerkers werken aan de bevestiging van een F16 vleugel in een houten maatwerk kist, ondersteund door een heftruck voor veilig transport.

Faes team werkt samen met militair personeel om een F16 vleugel in een op maat gemaakte verpakking te plaatsen in een industriële werkplaats

Faes medewerker bevestigt onderdelen in een houten op maat gemaakte verpakking voor een F16 vleugel in een industriële werkplaats

Faes medewerkers werken aan een op maat gemaakte verpakking voor een F16 vleugel in een industriële werkplaats

Vorkheftruck verplaatst maatwerk verpakking buiten een luchtvaartloods met personeel van Faes en Defensie aanwezig

Measuring in for perfect fitting packaging

Prior to on-site packaging, I visited Volkel Air Base on October 6 together with Luuk Gijsbers (engineer) to record the assignment. Important questions we had were, for example, how the tail will be transported, what are the vulnerable spots and what further requirements there were with respect to the custom packaging. Often we also work with technical drawings of the product, but in this case these were not released due to state secrets. So an extra nice challenge for The Packaging People to come up with a perfectly fitting solution!

State secrets and modern technologies

Thanks to the ability to take measurements through 3D scanning, we were still able to paint a very accurate picture of the tail. After this 3D measurement and mapping the vulnerable spots, we were able to start working on the design at Faes. After this was approved, several parts of the package were built in-house at Faes, after which they could finally be further assembled on location. The crate was later built literally as a sleeve around the tail at Volkel Air Base and was then ready just in time for the trip.

Faes-medewerkers en defensiepersoneel werken samen in een luchtvaartloods aan logistieke oplossingen voor de luchtvaartindustrie

The F-16 phase-out

This order was part of the NIDV Netherlands Industrial Fighter Aircraft Replacement Platform (NIFARP), in connection with the phase-out of the F-16, which is due to be completed in 2024. Where possible, the F-16s will be sold to other countries or commercial parties as part of the Defense Divestment Plan, as the Netherlands will fully commit to working with the new F-35. We, Faes The Packaging People, are proud to contribute to this program and look back on a great assignment for the Ministry of Defense, a customer with whom we have had a pleasant cooperation for many years.

Michel Prins

Accountmanager Safety & Security

Michel Prins is Account Manager at Faes and a specialist in Safety & Security. Thanks to his background at the Ministry of Defense and years of experience in the sector, he advises organizations on reliable packaging solutions for critical applications. He combines practical knowledge with technical expertise to package sensitive equipment safely and efficiently.

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Theme: Custom Design & Production