By Engineer Tylor Roberts
In 2023, the Travis Air Force Base Fire Department, located in Solano County, California, took a meaningful step toward modernization by incorporating 3D printing into department operations. What began as a personal hobby quickly became a practical and cost-effective resource that delivers significant savings and operational flexibility to the entire department.
What 3D printing means in the fire service
3D printing, also known as additive manufacturing, creates a physical object by building it layer by layer from a digital design. Depending on the printer and material, departments can produce items such as signs, labels, storage components, training aids and custom tools in-house rather than ordering them from an outside vendor.
The impetus for the new practice
After working with 3D printing for eight years, I recognized that my hobby could directly address several longstanding needs within the Travis AFB Fire Department. Recurring expenses for custom signage, long procurement lead times for specialized tools, and the desire for tailored storage solutions for job-specific equipment created an opportunity to apply additive manufacturing in a meaningful way. The goal was simple: Reduce costs, increase responsiveness, and provide the department with the ability to create customized solutions on demand.
Key players involved in the shift
The success of this program would not have been possible without the full support of the Travis Air Force Base Fire Department’s management team. Their openness to innovation and willingness to back this initiative provided the necessary resources and institutional support to transform a personal skill into an official departmental capability. This leadership endorsement was the critical factor that allowed the program to grow beyond initial experimentation.
General timeline
I have been 3D-printing personally since 2017, but my occasional projects expanded as the value became evident for the fire department.
The integration of 3D printing within the department officially began in 2023 and is now a consistent and reliable resource used across multiple functions within the fire department.
Success metrics and stories
The 3D printing program has delivered measurable financial and operational benefits. By producing all station signage in-house, the department saves thousands of dollars annually that would otherwise be spent on outsourced fabrication. Beyond signage, the 3D print lab has enabled the creation of custom storage solutions designed specifically for job-related equipment and the development of new tools for specialty applications.
The capability has also enhanced the department’s community outreach efforts. Nearly all toys and games distributed during Fire Prevention Week are now designed and printed internally, significantly reducing costs while allowing for greater creativity and customization.
Most importantly, the program has introduced valuable flexibility. The department can now design and produce needed items on demand rather than waiting weeks or months for external vendors, improving both efficiency and mission effectiveness.
Tips for replication
Fire departments and emergency service agencies interested in replicating this model can benefit from several practical lessons learned:
- Identify internal talent first. Many organizations already have personnel with personal experience in 3D printing. Locating these individuals and giving them the opportunity to apply their skills professionally is often the easiest way to begin.
- Start with high-impact, low-complexity projects. Station signage, equipment labels, storage solutions, and training or public education materials provide quick, visible wins that clearly demonstrate value and help secure continued support.
- Secure strong leadership support. Management buy-in is essential. Present a straightforward business case focused on cost savings, reduced procurement times and greater customization.
- Document everything. Track the cost of items that would traditionally be purchased externally versus those produced in-house. These savings figures become powerful evidence when requesting additional equipment or formal program recognition.
- Focus on practical utility. Prioritize projects that solve true operational or administrative problems. Custom tool creation, specialized storage solutions, and community engagement materials typically offer the strongest return on investment.
- Invest strategically. While a personal printer can serve as an excellent starting point, departments should plan to eventually invest in reliable printers and appropriate filament types suited to a fire station environment.
Final thoughts
The introduction of 3D printing at Travis Air Force Base Fire Department demonstrates that meaningful innovation does not always require large budgets or complex infrastructure. With the right combination of individual initiative and leadership support, other fire departments can achieve similar cost savings, flexibility, and creative capability.
ABOUT THE AUTHOR
Tylor Roberts serves as an engineer on B Shift with the 60th CES/CEF Fire and Emergency Services at the Travis Air Force Base Fire Department.
