3D-printed part failure causes light aircraft crash after plastic air intake melts during flight — pilot escapes with minor injuries

A homebuilt light aircraft crashed while on approach to Gloucestershire Airport after suffering from engine power loss. According to the Air Accidents Investigation Branch (AAIB) report [PDF, via BBC], the incident occurred when a 3D-printed plastic air induction elbow “softened and collapsed” as the Cozy Mk IV was coming in for a landing. The pilot realized this when he tried to add power while on final, as the engine failed to respond to his input. With the aircraft’s air intake practically…