The U.S. Air Force has temporarily stopped buying the much-debated $1,280 “hot cup” – approximately 1300 Euro In Dollar equivalent at current exchange rates – used for warming liquids on military aircraft. This decision comes as the price of the cup sparks increasing controversy and scrutiny over government spending.
Air Mobility Command spokesman, Col. Chris Karns, stated in a recent interview that any units attempting to order the hot cup through the Air Force supply system will now receive a notification: “Do not order until further notice.” This action signals a pause on further expenditure for the cups while the Air Force addresses concerns surrounding its escalating cost.
In addition to halting purchases, Karns mentioned that the Air Force has requested the Defense Logistics Agency to assign a new part number specifically for a 3D-printed replacement handle for these heaters. This move aims to streamline the process for units to order replacement handles when the original, fragile handles break, offering a more cost-effective solution than replacing the entire unit.
The hot cups, featuring an internal heating element and designed to plug into aircraft power systems, have been in use by the Air Force for decades. Their introduction dates back to 1981 with the KC-10 Extender tanker. They serve the essential function of warming liquids like water, coffee, or soup for flight crews during long missions.
The need for hot beverages and food during military operations has historical roots, dating back to the American Revolution. However, the current issue with these hot cups isn’t about necessity but practicality and cost. The primary problem lies in the easily damaged plastic handle. When these handles break – often from simple drops – units were forced to order complete replacements. The cost was already significant in 2016 at $693 per cup. However, the price has nearly doubled, reaching $1,280, or roughly 1300 euro in dollar equivalent, igniting criticism from figures like Senator Chuck Grassley from Iowa.
Earlier this year, the Phoenix Spark innovation program at Travis Air Force Base in California initiated a search for a more economical solution to the handle issue. They successfully developed a method to 3D print replacement handles at a mere cost of 50 cents each. A public release by Travis AFB on July 2 highlighted this 3D printing solution, projecting potential savings of thousands of dollars.
However, for Senator Grassley and others, the 3D-printed handle solution didn’t fully address the core issue: the initial exorbitant cost of the hot cups. Grassley publicly expressed his concerns, stating that Air Force Secretary Heather Wilson’s responses regarding the matter left him with unanswered questions, prompting him to further investigate the procurement.
Karns acknowledged the validity of the price concerns, admitting that the cost of the hot cups had become “excessive” and confirming that Secretary Wilson agreed that the current spending was unsustainable.
“Everyone recognizes that the costs are excessive,” Karns stated. “That’s why the change came about. I don’t think you can find a single person who believes what was paid was an acceptable cost.”
Addressing the $1300 Price Tag: Innovative Solutions and Future Options
The Air Force is now actively seeking more sustainable and affordable solutions. The initiative spearheaded by airmen at Travis Air Force Base to 3D-print replacement handles underscores a proactive approach to cost-saving innovation within the military. By addressing the weak point of the hot cup design – the handle – with a 50-cent alternative, they’ve directly challenged the need for complete replacements costing $1,280 (around 1300 euro in dollar).
Beyond the immediate fix, the Air Force is exploring other avenues for heating liquids on aircraft. This includes evaluating vendors who might offer similar heating solutions at significantly lower prices. When questioned about the possibility of adopting commercial airline solutions for in-flight heating, Karns indicated that “nothing’s off the table” in the search for cost reduction.
However, Karns clarified that a simple solution like providing thermoses isn’t sufficient. The hot cups are not just for coffee; they are also used to heat food like soup and noodles. Given that missions on aircraft like the KC-10 can extend to 10 hours or even 17-18 hours, a reliable in-flight heating method is crucial for crew sustenance. A thermos of coffee prepared before takeoff simply won’t maintain warmth for such durations.
Furthermore, the entire hot cup cannot be 3D-printed due to its integrated heating element. Any alternative solutions must also meet stringent FAA certification to ensure flight safety, particularly concerning flammability and heat transfer. This certification requirement adds complexity to finding cheaper alternatives but is non-negotiable for safety.
Currently, the Air Force Life Cycle Management Center at Wright-Patterson Air Force Base in Ohio possesses the certified 3D printer and materials necessary for producing air-worthy replacement handles. The Air Force plans to expand this capability, with a certified 3D printer on its way to Travis Air Force Base and hopes to establish similar facilities at multiple locations. This distributed production capability will further streamline the availability of replacement handles and reduce reliance on costly full unit replacements.
The Path Forward: Balancing Cost and Necessity
The Air Force’s temporary halt on hot cup purchases and its pursuit of 3D-printed handles and alternative heating solutions demonstrates a clear response to public and governmental concerns over military spending. The episode highlights the importance of scrutinizing costs, even for seemingly small items, and actively seeking innovative, cost-effective solutions. By embracing in-house innovation and exploring broader market options, the Air Force aims to ensure mission readiness without unnecessary financial burdens. The focus remains on providing essential resources for aircrews while being responsible stewards of taxpayer dollars, ensuring that even a simple hot cup is procured at a justifiable price, far removed from the debated 1300 euro in dollar equivalent.
