I had to fix my Radian pro, after an unexpected nose first hard landing (crash). The fuselage and one wing were broken, easy enough to fix. The hard thing was the wing retention tab that broke off thru the screw hole. I didn't think there was enough area at the break to reliably hold if glued, so I thought of a reinforcement for the repair.

I measured the tab, and 3D printed a form block and die set. The aluminum I used was .015 thick, so I allowed .018 clearance between the block and die.

The first press (by squeezing in the vise), was not too good. The aluminum sheared at the radiussed end instead of drawing. I softened the edges of the punch, and used a smaller blank without the holes to clear the guide pins. With a liberal application of oil, I got acceptable parts. There was a small crack at the bottom of the radiussed part, but the top and walls provided enough strength.

Epoxy secured the pan and the broken end to the tab. It turned out so well, I added a pan to the other unbroken side.

The plane is back together, and ready to go again.