The United States Air Force has temporarily stopped buying a controversial hot cup, priced at approximately 1300 Euros In Dollars (roughly $1,280 USD), designed for warming liquids on cargo and other aircraft. This decision comes amidst growing scrutiny over the exorbitant cost of the device.
Air Mobility Command spokesman, Colonel Chris Karns, stated in a recent interview that Air Force units attempting to order the specialized hot cup through the standard supply system will now encounter a message: “Do not order until further notice.” This procurement halt signals a significant pause in the acquisition of these expensive items.
In a proactive move to address another aspect of the issue, Col. 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 the hot cups. This initiative aims to simplify the process for units to order replacement handles when the original, more fragile handles break, offering a cost-effective alternative to replacing the entire unit.
The Air Force has been utilizing these hot cups, which incorporate an internal heating element to warm beverages like water, coffee, or soup, for decades. Their introduction dates back to 1981 with the KC-10 Extender tanker, highlighting a long-standing need for in-flight liquid heating solutions. These cups are uniquely engineered to integrate with aircraft power systems.
However, a critical flaw in the design has surfaced: the plastic handle is prone to breakage, especially when dropped. The absence of replacement handles in the supply chain has forced Air Force units to order complete new hot cups whenever a handle failed. This practice was already costly when the units were priced at $693 each in 2016. However, the price has since nearly doubled to 1300 euros in dollars, provoking strong criticism from figures like Senator Chuck Grassley, a Republican from Iowa, who has publicly questioned such expenditures.
The Phoenix Spark innovation program at Travis Air Force Base in California initiated a search for a more economical solution to the handle issue earlier this year. They successfully developed a method to 3D-print replacement handles at a mere cost of 50 cents per unit. Travis AFB publicized this 3D-printing solution on July 2nd, emphasizing its potential to “save thousands” of taxpayer dollars.
Despite these efforts, Senator Grassley and others remain concerned, questioning the fundamental necessity of a coffee cup costing nearly 1300 euros in dollars. In a statement released on Friday, Grassley expressed that the responses he received from Air Force Secretary Heather Wilson regarding this matter were insufficient, leaving him with further questions and a commitment to continue investigating the issue.
Col. Karns acknowledged the spiraling cost of the hot cups and confirmed that Secretary Wilson also believes the current pricing is unsustainable for the Air Force. “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.”
The Air Force is now actively exploring alternative methods for heating liquids on aircraft, including sourcing vendors who can offer comparable equipment at significantly lower prices. When asked about the possibility of adopting solutions used by commercial airlines for long-haul flights, Karns indicated that all options are being considered to reduce costs. “I don’t think anything’s off the table, other than figuring out how to reduce the cost,” he affirmed.
However, Karns clarified that a simple solution like providing pilots with Thermoses is not sufficient. The hot cups are also essential for warming food items like soup and noodles, crucial for aircrews on extended missions. Flights on aircraft such as the KC-10 can frequently last 10 hours or more, sometimes stretching to 17 or 18 hours, necessitating a reliable way to heat meals and beverages in flight, as pre-filled Thermoses would not maintain temperature for such durations.
Furthermore, Karns pointed out that the entire hot cup cannot be 3D-printed due to its integrated heating element. The Air Force must also adhere to strict FAA certification standards when considering cheaper alternatives, ensuring flight safety concerning flammability and heat transfer.
Currently, the Air Force Life Cycle Management Center at Wright-Patterson Air Force Base in Ohio is equipped with the certified 3D printer and materials required to produce airworthy parts. The aim is to expand this capability, with a certified 3D printer en route to Travis Air Force Base. The Air Force hopes to establish 3D printing capabilities at multiple locations to streamline the production of replacement handles.
