Wall Colmonoy Oklahoma City, a manufacturer and repair provider for military and commercial aerospace components, has secured a multi-year, multi-million-dollar contract from the United States Air Force (USAF). The award covers remanufacturing primary and secondary heat exchangers used in the F-16 Fighting Falcon. Included components are P/N 764967-7, identified by National Stock Number 1660-01-331-0068, and P/N 764967-5, identified by NSN 1660-01-046-0943. An exact contract value, number of components, performance period, and delivery schedule were not disclosed in the announcement.
F-16 aircraft remain in service with the United States and allied air forces worldwide. Wall Colmonoy’s contract brings the heat exchanger work back to Oklahoma City, where its facility specializes in designing, engineering, manufacturing, overhauling, and remanufacturing aerospace equipment. Production and repair processes available at the site include brazing, welding, machining, fabrication, assembly, and testing. Customers include original equipment manufacturers (OEMs) and businesses operating in the maintenance, repair, and overhaul (MRO) sector.
“We are delighted to bring this work back to Oklahoma City and continue our support of the U.S. Air Force’s F-16 fleet,” states Brian Martin, Director of Business Development, Wall Colmonoy Oklahoma City. “This award reflects our ongoing commitment to supporting aircraft readiness, delivering cost-effective solutions, and extending the service life of critical aerospace components.”
The firm has previously supported the manufacture, overhaul, and remanufacture of military aircraft heat exchangers, including as an early developer of overhaul and repair procedures. Its experience covers the high-temperature furnace brazing processes used in heat exchanger production. Its engineering and production capabilities allow aerospace parts to be returned to service instead of being replaced, supporting fleet readiness while reducing costs associated with replacement equipment. The USAF contract applies this established area of work to the two specified F-16 heat exchanger part numbers.
Oklahoma City operations extend beyond military heat exchangers to commercial aircraft exhaust equipment and related components. The facility manufactures Nicrocraft Aircraft Exhaust Systems, a range of newly manufactured aftermarket parts holding Federal Aviation Administration Parts Manufacturer Approval. Applications include aircraft produced by Beechcraft, Cessna, Cirrus, Aeronca, and Piper. Wall Colmonoy Oklahoma City also builds complete original equipment exhaust systems for general aviation aircraft and rotorcraft. Manufacturing partnerships cover systems for the Cirrus SR22T and Cessna 172S, as well as the Robinson R22, R44, and R66 helicopters.
Additive Manufacturing for Legacy Fleet Sustainment
While Wall Colmonoy’s contract relies on traditional brazing and machining processes, additive manufacturing is already gaining traction across U.S. defense sustainment programs tackling the challenges of obsolescence, tooling loss, and extended procurement timelines.
For instance, the U.S. Navy’s RESTORE laboratory used 3D scanning and 3D printing to repair legacy combat equipment after rainwater damaged an AN/TRC-194 antenna drive. Replacement components for the system, introduced in 1988, were obsolete, while the original tooling for its sand-cast pedestal was unavailable. Engineers scanned the antenna, converted its geometry into a CAD model, and developed a replacement cover to support continued operation.
More recent Navy programs have expanded this approach from individual repairs to a distributed sustainment system. Its Additive Manufacturing Center of Excellence has delivered more than 300 3D printed components for aging naval vessels, including reverse-engineered parts for 40-year-old 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.
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Featured image shows F-16 Secondary Heat Exchangers. Image via Wall Colmonoy.
