Maxwell Base Integrates VR Training for Grey Wolf Helicopter
Maxwell Air Force Base in Alabama is set to become the newest location within the U.S. Department of Defense to adopt advanced virtual reality training for aircraft maintenance. In a collaborative effort last month, the 908th Aircraft Maintenance Squadron partnered with technology provider Mass Virtual to begin the initial scanning process for developing extended reality (XR) training tools focused on the MH-139A Grey Wolf helicopter.
Mass Virtual, an industry leader in XR aviation training solutions, has been contracted by the United States Air Force to support the Integrated Technology Platform, a programme under the Air Education and Training Command aimed at modernising aircraft training infrastructure across military installations. XR, or extended reality, blends elements of virtual, augmented, and mixed reality into a seamless environment that enhances both learning and hands-on practice without the need for live equipment.
During the recent operation at Maxwell, the Mass Virtual team employed state-of-the-art technology, including LiDAR scanners and photogrammetry tools. These devices captured high-resolution depth data and overlapping imagery of the helicopter’s components, respectively, allowing them to recreate the aircraft with exceptional accuracy digitally. In total, 19 out of 44 designated maintenance procedures were recorded for the XR system. These included tasks such as replacing a rear tyre, attaching tow bars, and taxiing procedures for the Grey Wolf.
The aim of this initiative is to build a comprehensive virtual maintenance trainer that supports technical accuracy and situational awareness. The captured material included not just imagery but also ambient sound, standard video, and stereoscopic 3D footage. This thorough content acquisition ensures a rich, multi-sensory learning experience for maintainers, especially those serving as reservists with limited access to live aircraft.
Heading the technical side of the project from the 908th AMXS was Master Sergeant Jason Gessler, who coordinated the step-by-step documentation of each maintenance task. By narrating each process on site, he contributed to creating a dual-layered training experience, both auditory and visual, which adds depth to the virtual programme.
Training maintainers while preserving aircraft availability has always posed a logistical challenge. The new XR-based system helps solve this issue by allowing airmen to engage in lifelike simulations without removing operational aircraft from active duty. According to 908th AMXS personnel, this method represents a meaningful advancement in both safety and scalability of instruction.
Master Sergeant Michael Coleman, an avionics technician from the same unit, underscored the psychological benefit of such technology, noting that trainees often hesitate to work on real aircraft due to fear of causing damage. With virtual access, learners can become confident with equipment before ever stepping into a hangar, thereby enhancing job performance and safety outcomes.
Mass Virtual’s development cycle for XR content typically spans around six months when working with familiar aircraft models. However, given that the Grey Wolf is a new addition to the Air Force’s fleet, the team anticipates a longer timeline due to the additional data required for accurate rendering. Unlike the fixed-wing planes they’ve routinely scanned, helicopters bring unique spatial and structural challenges, according to the 3D art team involved in the capture process.
The adoption of this technology at Maxwell Air Force Base adds it to a growing list of 135 Department of Defense facilities already leveraging XR capabilities. With the Grey Wolf now becoming the 32nd Air Force aircraft integrated into the virtual hangar space, the move signals a broader commitment to digitised learning within military aviation.
This initiative highlights a forward-leaning approach to training and preparedness, designed to empower airmen with innovative tools that align with modern operational demands while reducing risk and increasing access for personnel across varying levels of experience.
