Fairmount Technologies Formally Receives APFIT Contract to Deliver XTRU™ Manufacturing Systems to U.S. Defense Sustainment Organizations
DERBY, Kansas — Fairmount Technologies (FT) formally received its contract under the Under Secretary of War for Research and Engineering (USW R&E) Accelerate the Procurement & Fielding of Innovative Technologies (APFIT) program, marking a major step toward deploying FT’s XTRU™ tooling-free manufacturing technology across the U.S. Defense sustainment enterprise.
As part of this effort, FT will produce and deliver a total of 18 XTRU machines to select core MRO depots and Aircraft Battle Damage Repair (ABDR) units. Machine deliveries are scheduled to begin in Summer 2027.
The contract moves the XTRU program from award selection into active machine production and fielding. FT will reconfigure its shop space to support machine production alongside ongoing R&D efforts, begin procurement of long-lead time subassemblies, and grow the technical and production teams responsible for machine assembly, software integration, testing, installation and customer support.
“This contract represents the transition of XTRU from a proven advanced manufacturing technology into an operational resource for the warfighter,” said Jordan Peter, General Manager of Fairmount Technologies. “Our team is proud to begin building and delivering systems that enable maintenance organizations with the right capabilities to produce critical airframe components faster and more agilely to improve readiness.”
Addressing a Critical Sustainment Challenge
Structural aircraft replacement parts can take several weeks, months—or, in some cases, more than a year—to manufacture and deliver. Traditional production methods often require large forming and machining systems in addition to part-specific tooling that must be designed, fabricated and validated before a replacement part can be produced.
These lengthy processes render aircraft unusable while maintenance teams wait for critical structural components.
FT’s XTRU Smart Manufacturing Cell replaces part-specific tooling with CNC programs and a digital manufacturing thread. The system is designed to allow qualified users to form, machine and joggle structural airframe components using compact, digitally controlled equipment.
When a manufacturing technical data package is available, the XTRU suite has the potential to reduce spare-part production timelines from months to days. The goal is to help reduce mission-impaired aircraft awaiting parts and increase warfighter readiness.
Eighteen Machines Supporting Depot and Forward-Based Operations
The APFIT acquisition will include:
Five XtruForm™ machines for tooling-free stretch forming
Five XtruMach™ machines for precision milling of structural profiles
Eight XtruJog™ machines for digitally controlled joggling
Together, the machines are intended to support rapid production of structural aircraft spares at major sustainment depots. Several systems will also be used to support Aircraft Battle Damage Repair field operations, helping bring manufacturing capability closer to the point-of-need.
The broader XTRU digital thread will allow manufacturing programs, setup instructions and technical data packages developed at central depots to be reused at other authorized locations. This approach will reduce duplicated engineering effort while supporting more consistent production across the sustainment network.
Scaling Production in Kansas
To execute the contract, FT is expanding operations at its Derby, Kansas, facility. Planned investments include dedicated mechanical assembly stations, electrical and hydraulic integration areas, additional inspection and production equipment, and expanded machine-testing capacity.
FT will also establish a new customer support capability with XtruForm, XtruMach and XtruJog systems. This will support customer training, machine acceptance activities, technical data package development, troubleshooting and long-term sustainment of fielded systems.
The APFIT program is expected to support significant growth at FT, including additional positions in production, machine integration, quality assurance, software engineering and customer support.
From Development to Deployment
XTRU technology originated from research conducted at Wichita State University, was spun off as a start-up company that advanced technology development through DOW SBIR and RDT&E funding in collaboration with Defense sustainment organizations.
Over three generations of development, FT has demonstrated XTRU systems through the production of thousands of Defense and commercial aviation components. The third generations of the XtruForm, XtruMach and XtruJog platforms were demonstrated at the Warner Robins Air Logistics Complex in January 2025.
The APFIT contract represents the next phase of that work: transitioning a demonstrated manufacturing capability into sustained operational use.
“This milestone reflects more than 15 years of development, testing and partnership,” Mrs. Peter said. “We are grateful to the defense organizations, technical experts, program sponsors, university partners and FT employees who helped advance the technology. We are now focused on executing well and delivering the first machines beginning in Summer 2027.”
As production progresses, FT will continue sharing updates on workforce growth, and machine delivery activities.
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