Shaking things up: 3D-printed tray stops mess on flights

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250721-F-DO467-1006

U.S. Air Force Staff Sgt. Joshua Morrison, a flight attendant assigned to the 1st Airlift Squadron, develops a smart tray in the SparkX Cell office at Joint Base Andrews, Md., July 21, 2025. The SparkX Cell, an innovation laboratory, provides the tools for Airmen to produce quality-of-life improvements in workplaces throughout Andrews. (U.S. Air Force photo by Staff Sgt. Alex Broome)

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250721-F-DO467-1028

Old salt and pepper trays demonstrate the impact of turbulence aboard a C-32A at Joint Base Andrews, Md., July 21, 2025. The new 3D-printed smart trays will prevent shakers from sliding and falling, mitigating spillage during turbulence on executive flights. (U.S. Air Force photo by Staff Sgt. Alex Broome)

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250721-F-DO467-1017

A laptop screen displays the Fusion360 digital schematics for an in-flight salt and pepper holding tray in the SparkX Cell office at Joint Base Andrews, Md., July 21, 2025. The smart tray, designed to fit into galley stowage carts, mitigates mess and clean-up requirements post-flight for aircraft transporting distinguished visitors at Andrews. (U.S. Air Force photo by Staff Sgt. Alex Broome)

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250721-F-DO467-1048

U.S. Air Force Staff Sgt. Joshua Morrison, a flight attendant assigned to the 1st Airlift Squadron, uses the Prusa XL 3D printer to build an in-flight salt and pepper holding tray in the SparkX Cell office at Joint Base Andrews, Md., July 21, 2025. Within a week of the initial request, Morrison produced a functional 3D prototype that was approved to develop 10 prints. (U.S. Air Force photo by Staff Sgt. Alex Broome)

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250721-F-DO467-1061

U.S. Air Force Staff Sgt. Joshua Morrison, a flight attendant assigned to the 1st Airlift Squadron, trims excess filament off a 3D-printed smart tray at Joint Base Andrews, Md., July 21, 2025. The 1st AS bought enough filament to produce an initial order of 10 smart trays. (U.S. Air Force photo by Staff Sgt. Alex Broome)

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250721-F-DO467-1138

U.S. Air Force Staff Sgt. Joshua Morrison, a flight attendant assigned to the 1st Airlift Squadron, demonstrates a 3D-printed smart tray to two members of the 1st Airlift Squadron at Joint Base Andrews, Md., July 21, 2025. Morrison collected measurements from the 89th Operations Group’s kitchen galley carts to produce a functional proof-of-concept demonstration. (U.S. Air Force photo by Staff Sgt. Alex Broome)

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250721-F-DO467-1158

From left, U.S. Air Force Staff Sgt. Joshua Morrison demonstrates a 3D-printed smart tray to Senior Airman Emily Boales and Staff Sgt. Thomas Morrow, all assigned to the 1st Airlift Squadron, at Joint Base Andrews, Md., July 21, 2025. The new design will minimize cleaning time and maintain professional optics for future executive flights. (U.S. Air Force photo by Staff Sgt. Alex Broome)

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250721-F-DO467-1283

U.S. Air Force Staff Sgt. Joshua Morrison, a flight attendant assigned to the 1st Airlift Squadron, boards a C-32A to test his 3D-printed smart tray at Joint Base Andrews, Md., July 21, 2025. The C-32A provides executive transport and broad communications capabilities to senior political officials at Andrews. (U.S. Air Force photo by Staff Sgt. Alex Broome)

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250721-F-DO467-1229

U.S. Air Force Staff Sgt. Joshua Morrison, a flight attendant assigned to the 1st Airlift Squadron, positions the new smart tray into the galley stowage cart aboard a C-32A at Joint Base Andrews, Md., July 21, 2025. The 3D-printed smart tray modernizes the previous system to securely hold salt and pepper shakers and mitigate spillage during turbulence on executive flights. (U.S. Air Force photo by Staff Sgt. Alex Broome)

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250721-F-DO467-1182

The 3D-printed smart tray rests inside the galley stowage cart aboard a C-32A at Joint Base Andrews, Md., July 21, 2025. The tray securely holds the salt and pepper shakers, mitigating spillage during turbulence on executive flights. (U.S. Air Force photo by Staff Sgt. Alex Broome)

JOINT BASE ANDREWS, Md. –

U.S. Air Force Staff Sgt. Joshua Morrison, a flight attendant with the 1st Airlift Squadron, designed and 3D-printed a smart tray to prevent salt and pepper shakers from spilling during turbulence on executive flights at Joint Base Andrews, July 21, 2025. Produced through the SparkX Cell innovation lab, the tray successfully modernized galley stowage systems, reducing cleanup time and improving presentation for distinguished visitors.

Joint Base Andrews

SparkX Cell

innovation