Transportation Secretary Sean Duffy's testimony before Congress exposes the dire state of America's air traffic control infrastructure.
According to Just The News, the Federal Aviation Administration has resorted to purchasing replacement parts on eBay and using 3D printing technology to maintain its aging computer systems, as revealed by Transportation Secretary Sean Duffy during a Senate Appropriations Committee hearing.
Duffy's alarming disclosure comes amid a series of critical system failures at major U.S. airports, including multiple outages at Newark International Airport and Denver International Airport.
The situation has become increasingly concerning following a devastating midair collision in Washington, D.C., that claimed 67 lives in January 2025.
The FAA's reliance on outdated technology has forced the agency to seek creative solutions for maintaining critical infrastructure.
During his testimony, Duffy explained that the federal government lacks reliable suppliers for vital components needed to keep the aging systems operational. The situation has become so desperate that officials must scour eBay for parts and, when unavailable, resort to 3D printing replacements.
President Donald Trump, responding to the January crash between an Army Black Hawk helicopter and an American Airlines regional jet, emphasized the urgent need for modernization. The administration has proposed implementing a comprehensive computerized system for control towers, moving away from the current patchwork of obsolete equipment.
The crisis has prompted the Transportation Department to develop an ambitious three-year modernization plan focusing on communications technology, surveillance systems, and digitization upgrades. The initiative requires substantial congressional funding to address the mounting safety concerns.
Newark International Airport has experienced three significant outages since late April, causing widespread flight delays and disrupting air traffic across the East Coast. The most severe incident occurred on April 28, when radar and communications systems failed, leaving controllers unable to maintain radio contact with aircraft for approximately one minute.
Denver International Airport faced similar challenges when several pilots lost communication with traffic controllers for up to six minutes due to a radio system failure. The outage affected the Denver Air Route Traffic Control Center, which manages airspace across nine states, including Arizona, Colorado, Kansas, Montana, Nebraska, New Mexico, South Dakota, Utah, and Wyoming.
These technical failures have revealed the fragility of the current system, with some facilities operating on limited backup frequencies. At the Denver facility, four primary radio frequencies were already non-operational when the fifth backup frequency failed.
A safety expert report delivered to the FAA 14 months before the fatal Washington D.C. crash highlighted severe staffing shortages and quality control issues. Transportation Secretary Duffy acknowledged these longstanding problems, stating:
We should've paid way more attention to it as a country. We've let [the air traffic system] age, and now we're seeing the cracks of that age play out in real time for us.
The report specifically warned about historically high overtime levels and increasing safety risks. Personnel shortages have forced controllers to work extended hours and make sudden flight plan changes, potentially compromising safety protocols.
The FAA's air traffic control system faces unprecedented challenges, with officials resorting to unconventional methods to maintain aging equipment. Transportation Secretary Duffy's testimony has exposed the extent of the crisis, including the agency's dependence on eBay purchases and 3D printing for critical replacement parts.
The administration's three-year modernization plan seeks to address these issues through comprehensive upgrades to communications technology and surveillance systems. However, implementation requires significant congressional funding and coordination across multiple agencies to ensure a successful transition to modern air traffic control infrastructure.
