Additive manufacturing (AM), also known as 3D printing, has emerged as a disruptive force in the defence sector, transforming the way defence-focused organisations design, produce, and maintain critical assets. This revolutionary technology has found applications across various domains, including the production of drones, submarines, replacement parts in the field, and addressing the challenges associated with obsolete components. In this article, we will explore how additive manufacturing is reshaping the defence industry, driving innovation, enhancing operational efficiency, and ensuring readiness in the face of evolving threats.
Additive manufacturing has revolutionised traditional manufacturing processes by enabling the creation of complex three-dimensional objects, layer by layer, using digital models. Unlike subtractive methods that involve cutting or shaping materials, additive manufacturing builds objects from the ground up, offering greater design freedom and flexibility. By utilising a diverse range of materials, including polymers, metals, and composites, additive manufacturing has the potential to enhance the performance, durability, and functionality of defence systems.
According to the ASTM International, there are seven categories of additive manufacturing processes, each with its own distinct characteristics. These categories include Vat Photopolymerisation, Material Extrusion, Powder Bed Fusion, Material Jetting, Binder Jetting, Sheet Lamination, and Directed Energy Deposition. These processes utilize various techniques such as Stereolithography (SLA), Fused Deposition Modelling (FDM), Metal Laser-Based Powder Bed Fusion, among others, to achieve the desired results. These ASTM-defined categories provide a comprehensive framework to classify the various types of additive manufacturing processes based on their underlying principles and material deposition methods.
Although additive manufacturing may seem like a new innovation to some, it was originally pioneered, in an industrial sense, by Charles Hull in the 1980s with the invention of Stereolithography (SLA), the first commercially available 3D printing technology. Over the years, additive manufacturing has made significant progress, with the development of techniques such as Fused Deposition Modelling (FDM) and Powder Bed Fusion Laser-Based (PBF-LB). In the 2010s, additive manufacturing gained traction in industries for prototyping and tooling applications, leading to wider adoption. The industry has experienced on average 26% growth for revenues generated through products and services combined, making it an estimated $18 billion dollar market in 2022.
Why is AM important to Defence sector:
Additive Manufacturing (AM) holds significant importance for the defence sector due to its impact on logistics, part performance improvement, new product development, and component repair. The flexibility and rapid prototyping capabilities of AM are instrumental in enabling the defence sector to quickly develop and iterate on new products, accelerating research and development cycles, fostering innovation, and facilitating technology integration.
AM also contributes to improving part performance by enabling the production of complex geometries and optimised designs. This results in lighter, stronger, and more efficient components, leading to enhanced overall system performance for defence applications. An emerging area of development in AM is its role in improving logistics.
In terms of logistics, AM enables point-of-need supply, allowing military units to produce essential parts in forward operating positions. This reduces reliance on traditional supply chains, enhances responsiveness, and operational readiness. Component obsolescence is another major challenge AM is tackling. Project TAMPA, for example, addresses the logistics challenges faced by the Ministry of Defence (MoD) in supplying obsolete items. By using AM, TAMPA aims to reduce lead times and costs associated with procuring these items, ensuring that aging fleets can remain operational without significant downtime or expenses.
Additionally, AM plays a vital role in the repair of components. By digitising and storing part designs, damaged or obsolete components can be reproduced on-demand, reducing downtime and ensuring mission readiness. Technologies such as Wire DED or Cold Spray are being evaluated by multiple organisations to determine their effectiveness in rapidly repairing key assets in the field or back at base, enabling continued operation or providing limp home capabilities.
Key Examples of How Additive Manufacturing (AM) is Being Explored and Implemented in the Defence Sector
Additive Manufacturing (AM) is making significant strides in the defence sector across various domains including Land, Sea, Air. Here are some key examples of AM’s applications in these domains, although it should be noted that these examples may not encompass the full extent of AM’s utilisation due to undisclosed activities.
Examples of Additive Manufacturing (AM) in the Air Domain (including Space):
The Aerospace industry has begun incorporating AM into their operations. Although AM components in current manned aircraft such as helicopters and jets are relatively limited due to the technology’s recent industrial adoption at the time of their development, there are emerging cases of AM finding its place in existing airframes or engines. For instance, Boeing has utilised AM to print transmission housings for Chinook helicopters and the F35 program have found cost-effective workarounds for replacement parts. While not publicly disclosed, it is likely that more extensive AM activities are taking place behind closed doors.
With the development of new airframes and engines, AM is expected to play a larger role. For instance, the UK’s TEMPEST fighter jet aims to produce 30% of its components using AM. The specific target percentage is less important than the potential performance gains that can be achieved by pragmatically incorporating AM in significant amounts.
It is worth noting that aviation is one of the most challenging industries for AM implementation due to the need for stakeholders to understand how AM parts will perform in real-world conditions. Unlike other manufacturing techniques with extensive material data, in-service part history, established supply chains, and industry standards, AM is still rapidly developing in these aspects.
Manufacturers like Boeing, who have successfully qualified and certified over 70,000 AM parts (across civilian and military aircraft) and gathered in-service data, are reaping the rewards of being early adopters. However, it should not be underestimated the amount of effort this is required for qualification and certification of a component. For metal PBF-LB components the cost could range from $1-1.5 million and 12-18 months, depending on part criticality and prior experience.
For unmanned aircraft, the development of new drone models provides ample opportunities for AM implementation. General Atomics, in partnership with Divergent, has created a modular system using large PBF-LB/M printers and robots to rapidly customise high-value drones for reconnaissance or tactical missions. By combining optimised lightweight designs and alloys, this approach significantly improves the performance of the drones.
In the realm of space, AM has been a driving force for technological advancements. Flight-critical hardware, including thrust chambers, pumps, impellers, RF antennas, waveguides, and brackets, are increasingly produced using AM. Companies like SpaceX and Relativity Space heavily rely on AM for their flight-critical hardware, with Relativity Space recently achieving a major success by printing the majority of their rocket components, including the engine, and successfully reaching orbit on their first attempt. This is providing governments with significantly lower costs to launch intelligence infrastructure such as satellites.
Examples of Additive Manufacturing (AM) in the Naval Domain
Additive Manufacturing is finding valuable applications in the naval sector across different types of vessels, including small craft, warships, and submarines. The use of AM onboard ships aims to provide critical spare parts, ensuring continuous operation without the need for shore-based resupply or returning to port. This capability offers significant logistical advantages for nations that can effectively utilise AM technology in a marine environment.
Deploying printers on ships poses challenges due to the dynamic sea environment and limited space. Practical considerations favour alternatives to powder bed fusion laser-based metal technology. Directed energy deposition and cold spray technologies offer rapid material deposition for urgent repairs or component production. Examples of onboard AM-printed components include handles, pump housings, tools, pressure fittings, and bronze anchors.
AM is also considered for meeting the demand in submarine construction, addressing component availability issues like large titanium castings. Collaboration with partners like IperionX enables the US Navy to produce recycled titanium powder domestically and utilize patented AM machines, reducing lead times and dependence on foreign-controlled supply chains.
Other potential uses of AM in the navy include printing full hulls of boats. The University of Maine’s Advanced Structures and Composite Centre, for instance, achieved a milestone by 3D printing the world’s largest boat called the 3Dirigo. This 25-foot (7.62-meter) boat was created in just 72 hours using a large thermoplastic 3D printer. Discussions continue regarding the practicality of directly replacing vessels with AM-printed counterparts, but there is also exploration of other applications, such as using AM systems to create moulds for composite materials or rapidly manufacturing expendable unmanned vessels, which may prove more pragmatic uses of the technology.
Examples of Additive Manufacturing in the land domain
Additive Manufacturing (AM) is making significant strides within the military domain, improving operations across various platforms, from armoured vehicles to infantry equipment. Here are some remarkable examples of AM in action:
In the United Kingdom, Babcock International Group is at the forefront of tackling the growing challenges of technical and commercial obsolescence. They have recently produced AM steel periscope system components for Titan and Trojan armoured vehicles. This achievement marks the first time any supplier to the Ministry of Defence (MOD) has manufactured such components to address these pressing .
The British Army is leveraging metal cold-spray printing technology to bolster unplanned repair capabilities. Working closely with the British Army’s Royal Electrical and Mechanical Engineers, Spee3D is spearheading the project to assess whether the technology can swiftly produce parts from well-known metal alloys to meet real-time needs in the field. The portable XSPEE3D printer has been designed to fit into a standard shipping container, enhancing its mobility. With all auxiliary equipment consolidated in one box.
Deployed manufacturing spaces are not new phenomena, one effort by the US Marines include the “Factory in a Box” (FIAB) concept. This portable Expeditionary Fabrication Shop can be set up in just 30 minutes upon arrival, enabling manufacturing and repairs in remote, infrastructure-limited areas. With metrology, additive and subtractive equipment, the FIAB allows engineers to reverse engineer damaged equipment, offering various manufacturing methods for critical component replacement or repair. Armed forces worldwide are exploring similar concepts. Smaller printers like the X7 Field edition from Marked Forged, housed in an impact-resistant and flame-retardant case with remote power generation, facilitate seamless operation in forward locations.
The war in Ukraine has underscored the practicality of AM in supplementing battlefield activities. AM technology has been instrumental in producing crucial items that were otherwise unavailable through conventional means. Protective gear, medical supplies, replacement parts, drones, and weapons accessories have been successfully printed, addressing urgent needs on the ground. In the first two months of the invasion of Ukraine one volunteer organisation estimated that they had printed collectively 10,000 parts in assistance of Ukraine.
The Future of Additive Manufacturing: Overcoming Challenges and Unlocking Potential
The additive manufacturing (AM) industry is poised for sustained rapid growth, projected to become a $100 billion dollar industry by 2032. However, as more users begin to explore this technology, key challenges must be continually addressed to ensure its successful adoption. Contextualising the use of AM is crucial to maximise its benefits, considering it as one of many manufacturing processes, each with their own advantages and limitations. Critical roadblocks stretch beyond technology improvements and include the availability of a skilled workforce competent in utilising AM technology and finding pragmatic routes to qualify and certifying AM-produced components for end use components.
One country at this forefront of tackling these issues is the United States government who is clearly demonstrating its commitment to leveraging AM technology. Initiatives such as the AM Forward program, announced by U.S. President Joe Biden in May 2022, aim to strengthen supply chains and increase domestic manufacturing by embracing AM. Notable manufacturers such as General Electric Aviation, Honeywell, Siemens Energy, Raytheon Technologies, and Lockheed Martin have already pledged their support and are actively working with the U.S.-based SME community to develop the supply chain. Through AM Forward, original equipment manufacturers (OEMs) will collaborate directly with their U.S.-based suppliers to demonstrate clear demand for additively-produced parts.
Moreover, funding in the Department of Defence is on the rise, with significant allocations earmarked in the latest 2023 defence appropriations bill. This indicates the growing recognition by governments and policymakers worldwide of the benefits of AM in strengthening national security objectives. It is now acknowledged that this technology, once primarily suitable for rapid prototyping, has evolved into a manufacturing process capable of producing end-use parts. As the AM industry continues to expand, it is essential to address challenges, foster innovation, and establish robust standards. By doing so, the potential of additive manufacturing can be fully realised, empowering industries and advancing national security goals in the years to come.