TYNDALL AIR FORCE BASE, Fla. -- U.S Airmen from the 325th Maintenance Group tested load cell technology of F-35A Lightning II aircraft during a weeklong trial at Tyndall Air Force Base, Florida -- the first use of the weighing system on the Air Force's newest fighter.
A load cell is a precision sensor that measures an aircraft’s weight by converting force into an electrical signal, allowing maintainers to capture accurate weight and balance data without traditional scales. The innovation could cut aircraft weighing times by nearly 50%, allowing jets to return to operations faster.
Traditional platform scales require maintainers to tow jets onto heavy ramps and can take a full day to complete weight and balance checks. Load cells are suitcase-sized devices that fit onto tripod jacks, simplifying the process and allowing crew chiefs to weigh aircraft more efficiently. Accurate weight and balance data are critical for flight safety performance as even the smallest miscalculation can affect an aircraft’s handling, fuel efficiency and ability to carry weapons or equipment.
The test adapted load cells used on F-22 Raptors to meet the unique requirements of the F-35A Lightning II.
“With the pull-on scales we have to level the jet by adjusting struts and tire pressure, whereas with the jacks you [don’t], making it quicker and more efficient [to get the jet’s weight],” said Tech. Sgt. Jonathan Kinney, 44th Aircraft Maintenance Squadron crew chief.
The innovation also carries benefits for deployed F-35 units by reducing their heavy equipment footprint. Instead of shipping a pallet of 400-pound platform scales, maintainers could transport load cells with more ease, reducing strain on Airmen and logistics.
Master Sgt. Dez Watson, 325th MXG quality assurance chief inspector, stated the effort highlights how repurposing this F-22 equipment could save time, calling it “innovation rooted in legacy.”
The idea gained traction at a Tyndall technical interchange meeting in April 2025, where maintainers proved to engineers that using the F-22 load cells was feasible and could safely be done to weigh the aircraft.
The team then went to Nellis AFB to test the concept because it was the next technical interchange meeting available to test on the F-35A. Encouraged by their results, the Airmen and engineers performed their final refinements at Tyndall to get precision and accuracy, quality assurance weight and balance on the F-35A.
“We proved that adapting existing equipment for the F-35 is not only possible, but it improves how fast we can get aircraft back to the line,” said Tech. Sgt. Israel Morales, 325th MXG quality assurance inspector. “The testing went better than expected. We saw consistent results each time, and that gave everyone confidence this process can work for the F-35.”
Engineers are still reviewing data, but leaders say the successful trials at Tyndall could set the standard for F-35A Lightning II weight and balance checks across the board and would be only available to the United States Air Force fleet.