The sole crew member sustained minor injuries in the crash, which destroyed the light aircraft

A plane crashed after a 3D-printed part softened and collapsed, causing its engine to lose power, a report has found.

The Cozy Mk IV light aircraft was destroyed after its plastic air induction elbow, bought at an air show in North America, collapsed.

The aircraft crashed into a landing aid system at Gloucestershire Airport in Staverton on 18 March at 13:04 GMT, after its engine lost power. The sole occupant was taken to hospital with minor injuries.

The Air Accidents Investigation Branch (AAIB) said in a report that the induction elbow was made of "inappropriate material" and safety actions will be taken in future regarding 3D printed parts.


The part, which was 3D-printed, softened and collapsed

Following an "uneventful local flight", the AAIB report said the pilot advanced the throttle on the final approach to the runway, and realised the engine had suffered a complete loss of power.

"He managed to fly over a road and a line of bushes on the airfield boundary, but landed short and struck the instrument landing system before coming to rest at the side of the structure," the report read. It was revealed the part had been installed during a modification to the fuel system and collapsed due to its 3D-printed plastic material softening when exposed to heat from the engine.

The Light Aircraft Association (LAA) said it now intends to take safety actions in response to the accident, including a "LAA Alert" regarding the use of 3D-printed parts that will be sent to inspectors.