The U.S. Air Force has temporarily stopped buying the much-debated $1,280 “hot cup”— approximately 1300 Euros Dollars at current exchange rates—used for heating liquids on military aircraft. This decision comes as the price of these cups has sparked significant controversy and drawn scrutiny over government spending.
Air Mobility Command spokesman, Col. Chris Karns, stated in an interview that Air Force units attempting to order the hot cup through the standard supply system will now receive a notification: “Do not order until further notice.” This measure is a direct response to the escalating costs and aims to reassess procurement strategies for essential, yet overpriced, equipment.
In addition to halting purchases, the Air Force is proactively addressing another issue: the fragility of the hot cup’s handle. Col. Karns mentioned that the Defense Logistics Agency has been tasked with creating a new part number specifically for a 3-D printed replacement handle. This initiative is intended to provide a more cost-effective solution when the original handles break, preventing the need to replace the entire unit.
The Air Force has been using these specialized hot cups, equipped with an internal heating element and designed to plug into aircraft power systems, for decades. Their introduction dates back to 1981 with the KC-10 Extender tanker. These cups are crucial for warming liquids like water, coffee, or soup during long flights, ensuring crew comfort and operational readiness.
The primary problem with these hot cups is the easily breakable plastic handle. Historically, the lack of replacement handles has forced units to order complete new hot cups whenever the handle failed. This practice was already costly when the cups were priced at $693 each in 2016. However, the price has nearly doubled to $1,280, or approximately 1300 euros dollars, triggering strong reactions, including criticism from Senator Chuck Grassley of Iowa.
The Phoenix Spark innovation program at Travis Air Force Base in California took a proactive approach to tackle the handle issue earlier this year. They developed a method to 3-D print replacement handles at a mere cost of 50 cents each. A public release from Travis AFB on July 2 highlighted this 3-D printing solution, estimating potential savings of “thousands of dollars.”
However, for figures like Senator Grassley, the 3-D printed handle solution doesn’t fully address the core concern: the initially high cost of the hot cups themselves. Senator Grassley publicly questioned why the Air Force was spending close to $1,300—roughly 1300 euros dollars—on a single coffee cup. Following Secretary of the Air Force Heather Wilson’s responses, Senator Grassley expressed further questions and committed to continued investigation into the matter.
Col. Karns acknowledged the validity of the price concerns, stating that the cost of the hot cups had become “excessive” and that Secretary Wilson agreed that the current spending was unsustainable. “Everyone recognizes that the costs are excessive,” Karns admitted. “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.”
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Battle over Air Force’s $1,300 coffee cups heats up
The Air Force, facing criticism for spending $1,280 each on in-flight reheating cups, will now use 3-D printing to repair them for just 50 cents, while Senator Chuck Grassley questions the necessity of such expensive cups.
By Stephen Losey
Col. Karns emphasized that the initiative to find a more affordable solution originated from airmen at Travis Air Force Base who recognized the financial impracticality of replacing the entire hot cup. Their innovative 3-D printing solution is a testament to their commitment to saving taxpayer money.
The Air Force is now actively exploring alternative options for heating liquids on aircraft. This includes evaluating vendors who can supply similar equipment at significantly lower prices. When questioned about considering commercial airline solutions for heating liquids on long flights, Col. Karns indicated openness to all possibilities, stating, “I don’t think anything’s off the table, other than figuring out how to reduce the cost.”
However, Col. Karns clarified that a simple switch to commercial thermoses isn’t feasible. The hot cups are not only used for coffee but also for warming food like soup and noodles, essential for aircrews on missions lasting 10 hours or more, sometimes extending to 17 or 18 hours. A thermos of coffee would not maintain temperature for such durations, and would not address the need for heating food.
Furthermore, 3-D printing the entire hot cup is not an option due to the integrated heating element. Any alternative hot cup solution must also meet stringent FAA safety certifications, covering aspects like flammability and heat transfer, to ensure flight safety.
Currently, the Air Force Life Cycle Management Center at Wright-Patterson Air Force Base in Ohio is equipped with certified 3-D printers and materials for producing air-worthy parts, including the replacement handles. The Air Force plans to expand this capability, with a certified 3-D printer soon to be installed at Travis Air Force Base, aiming to establish multiple locations capable of producing these cost-saving replacement handles.
About Stephen Losey
Stephen Losey is a defense and military affairs journalist.
