SAFE Structure Designs Delivers Custom Aviation Maintenance Tooling for U.S. Army's CH-47 Chinook Block II Fleet

The company's specialized tooling solutions improve safety, efficiency, and readiness for the Army's next-generation heavy-lift helicopter.

Mar. 25, 2026 at 5:52am

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SAFE Structure Designs, a U.S. defense engineering and manufacturing company, announced the successful design and delivery of a custom aviation maintenance tooling suite supporting the United States Army's next-generation Boeing CH-47 Chinook Block II helicopter fleet. The project required the development of specialized tooling used by Army aviation maintenance teams to safely remove, inspect, pressure-test, and reinstall fuel cell systems within the CH-47 Block II aircraft.

Why it matters

The custom tooling solutions developed by SAFE Structure Designs will play a critical role in helping the U.S. Army maintain operational readiness for one of its most important heavy-lift helicopter platforms. The tools improve safety, increase maintenance efficiency, and reduce aircraft downtime for the Army's new CH-47 Block II fleet.

The details

SAFE Structure Designs was awarded the contract after a previous contractor's tooling effort failed to meet the Army's technical and operational requirements. The company's engineering team designed and developed a series of specialized tools, including a fuel cell removal and installation cradle, a fuel cell pressure test system, and custom spreader bars and lift attachments, to streamline maintenance procedures for the CH-47 Block II's fuel cell systems.

  • SAFE Structure Designs was awarded the contract in 2026.
  • The company delivered the complete tooling system ahead of schedule and under budget in 2026.

The players

SAFE Structure Designs

An American defense engineering and manufacturing company specializing in mission-critical military support equipment.

United States Army

The military branch that operates the CH-47 Chinook Block II helicopter fleet and contracted SAFE Structure Designs for the custom tooling solutions.

Boeing

The manufacturer of the CH-47 Chinook Block II helicopter.

Johnny Buscema

The President and CEO of SAFE Structure Designs.

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What they’re saying

“We are humbled that the United States Army trusted SAFE Structure to step in and solve a critical challenge. Our team approached this mission with the same mindset we bring to every project—work hard, solve the problem, and deliver equipment that supports the men and women who defend this country.”

— Johnny Buscema, President and CEO of SAFE Structure Designs

What’s next

The United States Army has begun placing multiple bulk orders for the tooling systems as part of an outfitting effort for military installations across the United States that will support the new CH-47 Block II aircraft fleet.

The takeaway

SAFE Structure Designs' custom maintenance tooling solutions for the Army's CH-47 Chinook Block II fleet demonstrate the company's ability to rapidly engineer, manufacture, and deliver mission-critical equipment that improves safety, efficiency, and operational readiness for the U.S. military's aviation platforms.