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04 Apr 25. NASA Makes Progress on Advanced Drone Safety Management System. NASA is testing a new software system to create an improved warning system – one that can predict hazards to drones before they occur. The In-Time Aviation Safety Management System (IASMS) will monitor, assess, and mitigate airborne risks in real time. But making sure that it can do all that requires extensive experimentation to see how its elements work together, including simulations and drone flight tests. From agriculture and law enforcement to entertainment and disaster response, industries are increasingly turning to drones for help, but the growing volume of these aircraft will require trusted safety management systems to maintain safe operations.
“If everything is going as planned with your flight, you won’t notice your in-time aviation safety management system working,” said Michael Vincent, NASA acting deputy project manager with the System-Wide Safety project at NASA’s Langley Research Center in Hampton, Virginia. “It’s before you encounter an unusual situation, like loss of navigation or communications, that the IASMS provides an alert to the drone operator.”
The team completed a simulation in the Human-Autonomy Teaming Laboratory at NASA’s Ames Research Center in California’s Silicon Valley on March 5 aimed at finding out how critical elements of the IASMS could be used in operational hurricane relief and recovery. During this simulation, 12 drone pilots completed three 30-minute sessions where they managed up to six drones flying beyond visual line of sight to perform supply drops to residents stranded after a severe hurricane. Additional drones flew scripted search and rescue operations and levee inspections in the background. Researchers collected data on pilot performance, mission success, workload, and perceptions of the experiences, as well as the system’s usability. This simulation is part of a longer-term strategy by NASA to advance this technology. The lessons learned from this study will help prepare for the project’s hurricane relief and recovery flight tests, planned for 2027. As an example of this work, in the summer of 2024 NASA tested its IASMS during a series of drone flights in collaboration with the Ohio Department of Transportation in Columbus, Ohio, and in a separate effort, with three university-led teams. For the Ohio Department of Transportation tests, a drone flew with the NASA-developed IASMS software aboard, which communicated back to computers at NASA Langley. Those transmissions gave NASA researchers input on the system’s performance. NASA also conducted studies with The George Washington University (GWU), the University of Notre Dame, and Virginia Commonwealth University (VCU). These occurred at the U.S. Army’s Fort Devens in Devens, Massachusetts with GWU; near South Bend, Indiana with Notre Dame; and in Richmond, Virginia with VCU. Each test included a variety of types of drones, flight scenarios, and operators. Each drone testing series involved a different mission for the drone to perform and different hazards for the system to avoid. Scenarios included, for example, how the drone would fly during a wildfire or how it would deliver a package in a city. A different version of the NASA IASMS was used to fit the scenario depending on the mission, or depending on the flight area. When used in conjunction with other systems such as NASA’s Unmanned Aircraft System Traffic Management, IASMS may allow for routine drone flights in the U.S. to become a reality. The IASMS adds an additional layer of safety for drones, assuring the reliability and trust if the drone is flying over a town on a routine basis that it remains on course while avoiding hazards along the way.
“There are multiple entities who contribute to safety assurance when flying a drone,” Vincent said. “There is the person who’s flying the drone, the company who designs and manufactures the drone, the company operating the drone, and the Federal Aviation Administration, who has oversight over the entire National Airspace System. Being able to monitor, assess and mitigate risks in real time would make the risks in these situations much more secure.”
All of this work is led by NASA’s System-Wide Safety project under the Airspace Operations and Safety program in support of the agency’s Advanced Air Mobility mission, which seeks to deliver data to guide the industry’s development of electric air taxis and drones. (Source: UAS VISION/NASA)
03 Apr 25. Babcock International Group (Babcock) has been awarded a proof-of-concept contract by the UK Ministry of Defence (MOD) which will enable Ukraine’s armed forces to 3D print military equipment. Babcock as prime contractor will work with UK defence technology company QinetiQ to create digital drawings and Computer Aided Design (CAD) files of military equipment which then can be used to print parts in country. This innovative technology support comprises reverse engineering older parts to understand their function and design, enabling them to be digitally recreated on demand. Digital files will enable the manufacturing of parts during operations using a variety of methods including 3D printing, demonstrating Babcock’s ability to deliver defence support capability whenever and wherever it is required.
Tom Newman, CEO of Babcock’s Land Sector, said: “We aim to give Ukraine the capability to recreate the military parts that they need, where and when it really matters. This innovation builds on our engineering expertise and technology capability, giving us further opportunities to optimise 3D printing.”
Alan Hart, Managing Director of Science, Technology and Weapons for QinetiQ, said: “We are delighted to be working with Babcock to support Ukraine, and are immensely proud that QinetiQ is able to draw on our world-leading expertise in technical assurance to assist. This latest contract demonstrates QinetiQ’s unequalled expertise in material capability assurance, and commitment to support to the frontline, whether our own or those of our allies.”
This new contract forms part of Babcock’s steadfast support for Ukraine. Recently, Babcock announced an extension to our support for Ukraine’s armed forces which will ensure vehicles such as the Challenger 2 tank are repaired and restored as quickly as possible to the front line.Babcock manages the vehicle supply chain and spares, and shares its engineering expertise to train the Ukrainian military to conduct the repairs themselves.
31 Mar 25. Korean Army Integrates Meltio’s Metal 3D Printing Technology. Meltio’s unique wire-laser technology has been certified by the Army of the Republic of Korea (South Korea) to introduce robot-based metal 3D printers for the in-house production of parts. Meltio, in partnership with AM Solutions, has introduced its certified wire-laser metal 3D printing technology to the Korean Army, enhancing defense logistics with cost-effective, on-demand manufacturing and repair solutions. As part of this initiative, the Meltio metal 3D printer employs the Laser Wire Directed Energy Deposition (LW-DED) method. This advanced metal Additive Manufacturing (AM) technology works by melting metal wire with a laser beam and layering it to form a three-dimensional structure. Compared to other metal AM techniques, DED technology significantly reduces material waste, making it a cost-effective solution for manufacturing. Meltio systems are capable of reliably producing metal parts using Stainless Steel, Titanium, Copper, Inconel, and a wide range of other metal alloys. This achievement was made possible through a collaboration between Meltio and AM Solutions, extending the initiative to the Korean Army. Additionally, this marks the first time the Army of the Republic of Korea has decided to integrate metal additive manufacturing solutions for spare parts and repairs, gaining autonomy over conventional and more costly manufacturing processes. According to an article published by the South Korean magazine Kookbang and Meltio’s partner, AM Solutions, the Marine Corps Logistics Group is the first in the entire military to use robot-based metal 3D printers for logistics support. This advancement enables the rapid manufacturing of discontinued or hard-to-source repair parts. Field maintainability is expected to improve significantly, as the system can be relocated using a crane or forklift Thanks to AM Solutions, Meltio offers the Korean Army its unique Meltio Integration Kit for Industrial Robots. This system turns an industrial robot arm into a metal 3D printing system eliminating inherent size constraints, allowing for large-scale metal 3D printing, including complex geometries. It is the ideal platform for large-scale 3D printing, repair, cladding, and adding features to existing parts. The Meltio Engine seamlessly integrates with nearly any robotic arm manufacturer and interface available on the market. Its Meltio Space slicer software for robotic systems is fully compatible with ABB, Kuka, Fanuc, Yaskawa. Over the next two years, the Marine Corps Logistics Group plans to enhance its maintenance support capabilities by increasing operational proficiency and expanding field equipment, including mobile metal precision processing machines and generators
Adam Hourigan, Meltio Sales manager for APAC region, commented, “The defense sector is strategic for Meltio. Our technology is being validated by armies all over the world and for us it is very positive that thanks to collaboration agreements with relevant partners in Asia such as AM Solutions we are able to help with our different 3D metal wire welding printing solutions the army of the Republic of Korea to gain autonomy in manufacturing and creating metal parts in a reliable and sustainable way.”
Lieutenant Colonel Kim Seong-nam of the Republic of Korea, commander of the maintenance battalion, also said, “The introduction of metal 3D printers is significant not only for reducing operation and maintenance costs, but also for preventing delays in maintenance schedules due to limited procurement of repair parts. We will maintain the best logistics support system to enable stable maintenance support.”
Daejung Kim, AM Solutions CEO, stated, “The successful introduction of Meltio’s outstanding technology into the Republic of Korea marks a significant milestone in local manufacturing innovation.”
Kim also conveyed that this entry into the defense sector is just the beginning, and through a continuous partnership with Meltio, they aim to lead the Republic of Korea’s advanced industries in other sectors requiring additive manufacturing.
On the 19th of February, the Marine Corps Logistics Group announced, “We have introduced a container-type mobile metal 3D printer to quickly and smoothly provide logistics support, such as manufacturing parts in-house to cope with the limited procurement and discontinuation of repair parts for Marine Corps-specific equipment, including the amphibious assault armored vehicle (KAAV).” (Source: https://www.defenseadvancement.com/)
02 Apr 25. Accelerating its global leadership in sustainable production of advanced materials for additive manufacturing, 6K Additive and the German technology company TRUMPF, today announced that TRUMPF has qualified 6K Additive’s titanium metal powder for use in the TruPrint additive manufacturing systems. Both organizations have a strong customer base in aerospace as well as initiatives toward sustainability. This new qualification helps strengthen the opportunity for customers to leverage the premium titanium powder for their applications with the assurance that printed parts will meet their most stringent requirements and will have the lowest environmental impact.
“At TRUMPF we are dedicated to making our customer’s experience with our TruPrint systems deliver the highest level of performance and this includes the powder they use for their metal parts,” said Dennis Pede, Material engineer and scientist at TRUMPF. “TruPrint systems are open systems, allowing our customers to use the powder of their choice. However, for optimal process conditions and material properties, we recommend suitable material powders and work closely with our partners. Additionally, more and more our customers are asking us for metrics on the environmental footprint of our machines and the process. Having 6K Additive’s titanium sustainable powder added as an approved qualified powder, ensures customers get the quality assurance with the added value of driving down their CO2 footprint.”
Frank Roberts, President of 6K Additive added, “We continue to hear from our aerospace and defense customers asking us to help lower the barriers for qualification for their applications. The collaboration between our two companies did just that by ensuring the machine and powder are qualified ahead of their own internal qualification, which will streamline the customer’s process into production faster. We are excited to work with the TRUMPF team on titanium and other powders in our portfolio going forward.”
6K Additive is the world’s first producer of AM powder made from highly sustainable sources – offering a full suite of premium metal and alloy powders including nickel, titanium, copper, stainless steel, and refractory metals such as tungsten, niobium, and rhenium. Backed by the award-winning UniMelt® production-scale microwave plasma process, the technology precisely spheroidizes metal powders while controlling the chemistry and porosity of the final product with zero contamination and high-throughput. An independent LCA study (click here to download) validates that the approach makes it possible to achieve reductions in energy usage and carbon emissions of 90% for its nickel-based alloys and a 75% reduction in titanium alloys.
6K press releases are available here: https://www.6kinc.com/about/news/
About 6K
With sustainability at its core, 6K has developed UniMelt®, a proprietary advanced microwave plasma production system, to transform engineered materials into revolutionary products that advance industries across additive manufacturing, renewable energy, aerospace, consumer electronics, and more. 6K represents 6000 degrees, both the temperature of the operation of UniMelt®, the world’s only microwave production scale plasma system, and the temperature of the sun’s surface. 6K was founded in North Andover, Massachusetts. The 6K Energy division is focused on the production of low-cost, sustainable, and domestically produced battery material accelerating the pace of battery production and adoption of electric vehicles. The 6K Additive division specializes in sustainably sourced, AM metal powders production and reclamation, using a proprietary milling and cleaning process that ensures contamination-free, high-quality powders. For more information, visit www.6Kinc.com.
About TRUMPF
TRUMPF is a high-tech company offering manufacturing solutions in the fields of machine tools and laser technology. It drives digital connectivity in manufacturing through consulting, platform products and software. TRUMPF is one of the technology and market leaders in highly versatile machine tools for sheet metal processing and in the field of industrial lasers. In 2023/24, TRUMPF employed 19,018 people and generated sales of 5.2 bn euros. With about 90 companies, the TRUMPF Group is represented in nearly every European country as well as in North America, South America and Asia. The company has production facilities in Germany, France, the United Kingdom, Italy, Austria, Switzerland, Poland, the Czech Republic, the United States, Mexico and China. (Source: PR Newswire)
02 Apr 25. XTI Aerospace, Inc. (NASDAQ: XTIA), a pioneer in VTOL and powered-lift aircraft solutions, today announced the launch of the XTI Aerospace Prototyping and Innovation Lab within The HIVE in Grand Forks, North Dakota. The HIVE is a one-of-a-kind hybrid business accelerator & incubator focused on vertical takeoff and landing (VTOL) and unmanned aircraft systems (UAS). This new lab is designed to accelerate the development of XTI’s flagship powered-lift aircraft, the TriFan 600, initially focused on advancing the subscale model, code-named “Sparrow,” and progress toward the construction of a more advanced model, “Kestrel,” which will be crucial in enhancing key elements such as flight control systems and aerodynamics. Under the leadership of Professor Robert Lunnie, an expert in VTOL systems and an Aerospace Professor at the University of North Dakota, the team will work to optimize the aircraft’s performance capabilities and develop a cutting-edge flight control center. Professor Lunnie has assembled a highly skilled team dedicated to the development of XTI’s subscale models. XTI Aerospace anticipates that this new lab will help to not only enhance the design and flight capabilities of the TriFan 600 but also contribute to the broader advancement of aviation technology. By leveraging The HIVE’s collaborative environment and utilizing the expertise and resources within the Grand Forks aerospace community, XTI is positioning itself to remain at the forefront of the VTOL and powered-lift industries.
“We are excited to advance the next generation of TriFan 600’s subscale models, focusing on critical flight control and aerodynamics systems,” said Tobin Arthur, Chief Strategy Officer of XTI Aerospace. “With Professor Lunnie’s leadership, and strong local support and resources, the work at the XTI Prototyping and Innovation Lab will bring us closer to delivering the transformative TriFan to the market.”
Brandon Bochenski, Mayor of the City of Grand Forks, added, “Grand Forks is rapidly becoming a hub for aviation innovation, with key collaborations between the United States Air Force, various government agencies, the University of North Dakota, and the HIVE incubator. XTI Aerospace’s arrival strengthens our position as a leader in aerospace technology and we look forward to being a part of accelerating the TriFan 600’s path to first flight.”
Professor Lunnie stated, “Our team is highly motivated and eager to push the boundaries of aerospace innovation. We are committed to meeting and exceeding key milestones that will ultimately shape the future of air mobility. I am excited to have Professor Lunnie and XTI Aerospace collaborating at The HIVE,” said Johnny Ryan, Executive Director of the HIVE. “Their work epitomizes the collaborative ecosystem we have fostered in Grand Forks. XTI’s presence is a big step in our evolution from being a leading UAS market player to a broader mission incorporating all of VTOL and powered-lift markets.” (Source: PR Newswire)
02 Apr 25. HRL Laboratories, LLC has demonstrated proof-of-concept on a unique approach to achieve a silent pumping system that replaces traditional mechanical moving parts with an electric current and a magnetic field. This work is being performed under Defense Advanced Research Project Agency’s (DARPA) “Principles of Undersea Magnetohydrodynamic Pumps (PUMP)” program.
HRL’s new device uses a recirculating electrochemical hydrogen cell which enables a prototype magnetohydrodynamic (MHD) pump that could be 70% efficient as well as highly reliable – with a lifespan of more than 5 years. Key design benefits:
- Nearly eliminates gas bubbles – producing 95% fewer bubbles than traditional electrolysis cells – to deliver quiet, gas-free pumping
- Produces no oxidative or corrosive elements (O2 or Cl2) which degrade electrode performance over time
Magnetohydrodynamic (MHD) pumps:
MHD pumps, which generate force from a magnetic field acting on an electric current flowing through seawater, require no rotating mechanical components. This approach significantly reduces noise while simultaneously increasing reliability in comparison to conventional propeller- or impeller-based systems. In a typical MHD pump, a DC electrical current is passed through a volume of seawater, which interacts with an applied magnetic field, resulting in a Lorentz force on the ions in the water. As the ions accelerate, they drag the water molecules and generate thrust.
HRL’s concept includes uniquely tailored gas-diffusion electrodes in its MHD model. This innovation ensures that the hydrogen gas generated at the cathode does not form bubbles but instead diffuses-out to the back side of the electrode. The resulting H2 gas is then routed to the back side of the anode where it diffuses-in and is consumed. This completes the recirculation loop while preventing corrosive oxygen and chlorine bubbles from forming at the anode.
“With the successful demonstration of a viable method to achieve an efficient, quiet and reliable MHD pump, we hope that HRL will next have the opportunity to build a complete prototype test system for the U.S. Navy for further testing,” said Jason Graetz, principal investigator at HRL Laboratories.
History of magnetohydrodynamic (MHD) drive technology:
Since the 1960s, academic, commercial and military researchers have attempted to realize a novel form of maritime propulsion involving no moving parts – no propeller, no drive shaft, no seals – just magnets and an electric current that silently propel a marine vessel through water. Developers have had some success over the decades demonstrating MHD drive technology on a small scale, but it has been inefficient and impractical for full-scale systems. HRL’s new approach to MHD offers a promising solution to overcoming some of these challenges.
Notable partners:
- General Atomics will design and build the high-temperature superconducting (HTS) magnets required for the MHD pump.
- University of Illinois will provide experience in electrochemical and corrosion modeling to develop a modeling and simulation toolset that will guide the electrode design to meet the project’s specifications.
HRL Laboratories, LLC, California (www.hrl.com) pioneers the next frontiers of physical and information science. Delivering transformative technologies in automotive, aerospace and defense, HRL advances the critical missions of its customers. As a private company owned jointly by Boeing and GM, HRL is a source of innovations that advance the state of the art in profound and far-reaching ways. (Source: BUSINESS WIRE)
02 Apr 25. The UK Ministry of Defence (MOD) has published its first Defence Advanced Manufacturing Strategy. It highlights additive manufacturing as crucial to the British military’s strategic roadmap, identifying 3D printing’s vital role in strengthening supply chain resilience. The document emphasizes the urgency of accelerating additive manufacturing adoption in the UK’s defense sector. To achieve this, the MOD outlines three core initiatives: investing to incentivize industry, adapting policies to remove barriers, and integrating additive manufacturing into the defense supply chain. Key 3D printing benefits for defense include faster production, shorter lead times, access to obsolete parts, and improved sustainability. In 2021, the Defence Science and Technology Laboratory (Dstl) identified obsolescence as the top supply issue affecting military operations, impacting both old and new platforms. With over 1.3 m items in its inventory, the MOD sees 3D printing as a solution for many obsolete components. Britain’s defense leadership believes additive manufacturing will significantly improve platform and equipment availability. A Defence Innovation Unit (DIU)-commissioned report found that 3D printing 15% of the defense inventory could save £110M over the next 15 years. After that, the annual net benefit could reach £35.5M. According to the new defense strategy, 3D printing represents the “first step” toward the MOD’s broader adoption of other advanced manufacturing technologies.
“This strategy outlines our intent to embrace AM in new designs, to help resolve obsolescence and to increase our competitive edge through development of expeditious battle damage repair techniques,” commented Vice Admiral Andy Kyte, Chief of Defence Logistics and Support.
“This exciting technology has been in existence for some time, and defence must now realise the latent benefits it offers, in terms of operational availability, improved supply chain resilience and efficiency.”
The MOD’s additive manufacturing vision. Image via the Ministry of Defence.
Introducing the MOD’s Defence Advanced Manufacturing Strategy
Conflict in Ukraine and hostilities in the Middle East are worsening supply shortages, affecting access to key products and raw materials. These global challenges have increased the need for improved supply chain resilience. Personnel cuts in the Armed Forces and Civil Service, along with shrinking fleet sizes and ageing equipment, have further reduced availability, productivity, and efficiency. The MOD is turning to additive manufacturing to address these issues. Its new Advanced Manufacturing initiative shows how 3D printing can create dispersed supply networks of qualified suppliers. This approach aims to reduce lead times, tackle obsolescence, and improve sustainability. Four key pillars are central to the MOD’s additive manufacturing vision. These are design sources, a digital thread, certification, and mobile production capabilities for fabricating parts close to the point of need. Design sources generate 3D printed parts. This includes designing for additive manufacturing (DfAM) of new components or using reverse engineering to enable 3D printing of existing parts. The digital thread securely transmits sensitive design information from a design library to the 3D printer. It also allows users or manufacturers to send requested changes back to the designer. Ensuring cyber-security and consistent information across transmissions is crucial. The MOD is currently exploring how to create a unified, fully integrated digital service that can link with design libraries. The finalized design is certified before being deemed fit for military operations and 3D printed, sometimes near the frontlines. These stages will reportedly exist within a circular economy based on 3D printing material recyclability and reusability. The British military is also working to recycle high-end scrap metal into new metal 3D printing feedstock. For instance, British engine manufacturer Rolls-Royce recently partnered with the MOD to convert old Tornado fighter jet components into new 3D printed jet engines. Called Tornado 2 Tempest, the new initiative has already been used to 3D print components for the Orpheus jet engine concept, which supports the Future Combat Air System (FCAS) program.
How to increase adoption of additive manufacturing for defense
The Defence Advanced Manufacturing Strategy outlines the MOD’s strategy for accelerating 3D printing adoption and development within the UK defense sector. To incentivise industry, additional investment will be used to foster 3D printer adoption, either directly or through partnerships with additive manufacturing companies. This will include embedding 3D printing in existing and future designs and digitizing strategically important inventory and spare parts. It will also work to clarify how digital information can be securely transmitted from industry to MOD units and Front Line Commands (FLC). Unlocking constraints is another key pillar of the MOD’s additive manufacturing strategy. This will see the MOD work with industry partners to create accessible cross-functional processes that adhere to updated policies and drive adoption. Additionally, it will create a “knowledge hub,” improving access to critical information. The MOD also plans to develop new metrics to improve tracking of financial and non-financial 3D printing benefits. The MOD will design and create networks of supply, allowing 3D printing technology to be brought into the defense supply chain. Equipment, training, and consumables will be standardized, making them accessible through regular supply channels to meet industry standards and qualifications.
New partnerships between industrial partners, FLCs, and MOD units will be encouraged. The goal is to facilitate rapid learning and build trust through “trusted agent status” in an extended ‘hub’ and ‘spoke’ supply network. Inter-industry partnerships will also be incentivized to enhance resilience and improve 3D printing capabilities. Additionally, the MOD plans to form a strategic partnership with the UK High Value Manufacturing Catapult to drive efficiencies and benefit the UK industrial base.
These strategic priorities will guide a program of work, involving the MOD, industry, and the research community. A new governance structure will not be created for this. Instead, the program will be managed by one of the MOD’s existing steering groups.
3D printing in the British military: advantages and challenges
According to the MOD, the main benefit of additive manufacturing is addressing shortfalls in inventory items, due to technical or commercial obsolescence. 3D printing can also reduce lead times and create a more resilient, agile, and dispersed supply network. The British military has already demonstrated the value of 3D printing for defense applications. In 2021, the Chief of Defence Logistics and Support (CDLS) commissioned Project TAMPA. This ongoing initiative seeks to establish a network of suppliers capable of 3D printing military-grade spare parts on demand and at the point of need. According to the MOD, this project has already validated its additive manufacturing vision, confirming that increasing industry incentivization is key to growing adoption. British forces have actively leveraged 3D printing since at least 2016, with various MOD units and FLCs establishing AM centers to support battle damage repair operations. This work has mainly been completed independently, with each unit developing its own 3D printing processes and digital threads. Elsewhere, the Atomic Weapons Establishment (AWE) is using 3D printing to produce complex parts, while the DE&S Defence Electronics and Components Agency (DECA) is 3D printing prototypes. Another MOD organization leveraging additive manufacturing is The Submarine Delivery Agency (SDA). According to the Advanced Manufacturing Strategy, the SDA is using 3D printing to support In Service Submarines (ISS), Dreadnought, and Ship Submersible Nuclear (Attack) (SSN(A)) programmes. The ISS uses additive manufacturing to 3D print replacement components, conduct maintenance, and enhance supply chain resilience to improve submarine availability. 3D printing is being used in the SSN(A) to increase the rate of platform production.
The MOD claims that there is currently “no compulsion” for its manufacturing partners to accelerate 3D printing adoption to improve supply chains. It also highlights several key challenges constraining additive manufacturing development in the UK. For example, the MOD emphasized the need for more agile routes to the market, particularly when sourcing obsolete parts. It suggests creating separate supply chains for 3D printed components to avoid delays from traditional methods. This is because the benefits of AM, such as faster production and quicker responses, would be lost if the supply process is slowed. Interoperability challenges are also highlighted. Project TAMPA has proved that the pace of 3D printing development and increased machine versatility can cause 3D print files to quickly become obsolete. Even when using the same 3D printing method, different 3D printers often produce different results, hampering repeatability. TAMPA also found that a range of relevant 3D printing standards do not exist, with ASTM now working to improve access to the standards it has created. The MOD also identifies challenges related to through-life support, training, access to consumables, digital thread uncertainties, and high manufacturing costs.
Additive manufacturing enhances global defence capabilities
Beyond the UK, additive manufacturing is gaining traction in the global defense sector. The US, in particular, is investing heavily to expand its 3D printing-enabled supply chains. The US Department of Defense recently added $9.85 m to an existing agreement with 3D printing firm X-Bow Launch Systems. This contract, now worth $28.67 m, sees X-Bow develop 3D printed solid rocket motors (SRM) for US missiles. Similarly, rocket engine manufacturer Ursa Major recently received $12.5 m from the US Navy and the Office of Strategic Capital (OSC) to scale the production of its own 3D printed SRMs. Using its Lynx 3D printing technology, the Colorado-based company will design, manufacture, and test a new SRM prototype for missiles critical to national security. This follows earlier news that the firm is 3D printing the Navy’s Mk 104 dual rocket motor, which powers the SM-2, SM-3, and SM-6 missiles. In other news, Spanish 3D printing OEM Meltio recently saw its technology deployed by the Republic of Korea Army. This marks the first time Meltio’s DED 3D printers have been validated by a military in Asia, expanding its global footprint following earlier integrations by US, French, and Spanish forces. (Source: Google/https://3dprintingindustry.com/)
02 Apr 25. Singapore’s DSTA, Thales to develop AI tech for combat systems. Singapore’s Defence Science and Technology Agency (DSTA) and Thales have established a joint laboratory aimed at advancing AI-enabled technologies to enhance the combat systems used by the Singapore Armed Forces (SAF). This collaboration will initially concentrate on creating solutions for counter-uncrewed aircraft systems (C-UAS) and advanced sensing. To date, they have jointly created sophisticated AI algorithms that enhance the ability of combat systems to adapt and respond to the rapidly changing dynamics of drone-based threats. The outcomes were recently showcased at the Singapore Defence Technology Summit held between 18-20 March 2025. The partnership between DSTA and Thales was first formalised through a memorandum of understanding in 2022 to enhance collaboration on smart technologies and system supportability. The Co-Lab is an outcome of this agreement. This new initiative marks a significant progression in the strategic alliance between DSTA and Thales, highlighting their commitment to equipping the SAF with capabilities to address both conventional and unconventional security challenges. In 2023, DSTA signed a ‘master agreement’ with Thales, which focused on streamlining the establishment of long-term service contracts. This covered areas such as support, maintenance, operational availability, and local development. Over the past five months, engineers from both organisations have worked together to create ML-enabled software modules. These modules reduce false alarms in drone detection, thereby enhancing radar sensor performance. With the integration of AI, operators and end-users benefit from improved situational awareness, enabling quicker and more precise drone detection and classification.
Thales International president and CEO Pascale Sourisse said: “Thales’ AI for critical systems must meet the stringent reliability, safety and security requirements for armed forces worldwide. It is a true recognition when our customers trust us to co-develop solutions alongside them that address the pain points and challenges of the end-user. We have achieved the outcomes of the MoU in a relatively short span of time, with our teams harnessing AI to create solutions with real-world implications. This Co-Lab with DSTA speaks to the years of collaboration between us and our joint commitment to provide the best technologies for the SAF and the Singapore Ministry of Defence.”
Thales also contributes through its Defence Hub in Singapore, which provides local expertise for the support and maintenance of systems currently deployed by the armed forces. This hub plays a role in the ongoing partnership with DSTA and the Ministry of Defence. Singapore’s defence budget has increased from $11.4bn in 2021 to an estimated $17.7bn in 2025, according to a report by GlobalData titled “Singapore Defense Market 2025-2030”. Additionally, Singapore’s acquisition budget saw a rise from $2.1bn in 2021 to $3.3bn in 2025, growing at a compound annual growth rate of 12.4%. (Source: army-technology.com)
02 Apr 25. Green Hills Software, the worldwide leader in embedded safety and security, today announced the expansion of its industry-leading products and services for microcontrollers by adding support for the newest Texas Instruments (TI) AM26x high-performance microcontrollers (MCUs) including the AM263x, AM263Px, and AM261x MCU portfolios. Green Hills Software’s ISO 26262 ASIL D-certified µ-velOSity™ real-time operating system (RTOS) provides the small footprint and safety-certified high-performance software foundation while the MULTI® integrated development environment (IDE) enables software developers to reduce the development and debug time required to create products that use AM26x MCUs. This integrated platform is ideal for automated factories and software-defined vehicle electronics that require safety-certification, real-time processing, advanced motor-control topologies, and analytics at the edge. To streamline development for functional-safety solutions in multicore configurations, Green Hills offers a highly integrated safety-certified software platform that reduces the development time for the increasing lines of code and complexity today’s embedded systems are facing. The Green Hills solutions for the AM26x MCU portfolio cover a wide range of safety certifications, such as industrial (IEC 61508), rail (EN 50128/50657) and automotive (ISO 26262).
“The AM26x high-performance microcontrollers offer the real-time control features needed to serve motor control and digital power applications,” said Na Kong, Automotive Application Specific MCU Product Line Manager at TI. “Complementing these MCUs with the Green Hills safety-certified solutions offers our customers an easy-to-use, streamlined development path to get to market quickly for their safety-critical designs.”
“Green Hills, in collaboration with Texas Instruments, is enabling its customers with highly integrated, optimized software and hardware solutions for developing advanced, next-generation safety systems,” said Dan Mender, Vice President, Business Development at Green Hills Software. “The availability of this combination ensures rapid development, efficient debugging, and unmatched optimization, while enabling cost-effective, timely delivery of safety-certified solutions across many industrial and automotive applications.”
The AM26x MCU safety solutions from Green Hills Software are a complete offering that simplify creating, debugging, and deploying software for production-focused designs.
Simplified and Streamlined Development
- Integrated and Validated – The Green Hills products are tightly integrated with AM26x MCUs and include:
o µ-velOSity RTOS – safety-certified, small footprint, simple API, efficient execution
- TI Driver Porting Layer (DPL) Integration – instant access to complete device driver support for the AM263x/AM263Px/AM261x
o MULTI IDE and multicore debugger with TimeMachine® that debugs forward and backward in program execution
- TI SysConfig Integration – visualization and automation for AM26x MCU driver configuration
- History® Viewer – intuitive visualization of system events over time, correlated to source code
- Safety-certified C/C++ optimizing compilers and run-time libraries – highest performance, smallest code size
- MISRA C Adherence Wizard – Integrated enforcement of MISRA C rules
- DoubleCheck™ – for user-based static source code analysis at the time of link and compile
o Green Hills Probe for high-speed, multicore trace and JTAG debugging and board bring-up
- Find and Fix Bugs Faster – Time-saving features include multicore OS-aware debugging, trace-powered TimeMachine back-in-time debugging and History system event visualization.
- Efficient Use of Processor Resources – Green Hills Optimizing Compilers for C/C++ produce the smallest code with the highest performance.
- Resolve Software Problems Sooner – Static source code analysis with DoubleCheck automatically runs during compilation, enabling engineers to detect and resolve problems more efficiently and earlier in the development cycle.
Satisfying Safety- and Security-Critical Requirements
- The µ-velOSity RTOS and Green Hills Compilers and run-time libraries are certified to ISO 26262 ASIL D (Automotive), IEC 61508 SIL 3 (Industrial) and EN 50128/50657 SIL 4 (Railway)
- The safety team at Green Hills offers services to help customers design and certify their safety systems
- The AM26x MCU portfolio has multiple pin-to-pin compatible devices with up to four 400MHz Arm® Cortex®-R5F cores that can be programmed to run in lockstep or dual-core mode supporting ASIL D
- System MPU and a dedicated MPU per Arm Cortex-R5F core
- Other safety and security hardware features include: cryptographic acceleration and secure boot through a Hardware Security Module (HSM), Error-Correcting Code (ECC), Built-In Self-Test (BIST) and other processor integrity checking
Availability
The safety-certified µ-velOSity RTOS and MULTI IDE from Green Hills Software for the AM26x MCU portfolio are available today for use on the TI AM26x Launchpad hardware platforms. For more information, go to: https://www.ghs.com/products/sitara-am263x.html.
31 Mar 25. US Army to deploy integrated data layer for NGC2 at division level before next Project Convergence. The integrated data layer is a user interface where sensors from multiple domains can work together to supply information on enemy targets and other data the warfighter needs to make important calls. The Army plans to have its Next Generation Command and Control’s (NGC2) integrated data layer fully operational at the division level before next year’s Project Convergence Capstone (PCC) event, Army senior leaders said today. The integrated data layer is a user interface where sensors from multiple domains can work together to supply information on enemy targets and other data the warfighter needs to make important calls. It’s a key part of the technology stack that makes up NGC2, and it creates a framework where, for example, artillery, operational, aviation and other systems can talk to each other so the warfighters operating these systems don’t have to digest the various data separately.
“We, on this side, kind of owe the Army an integrated data layer that then we can build applications just like the ones that are on your phone, where warfighting systems can reach you and use that same data, and we’re not building separate pieces of transport, complicated spaghetti charts that connect the boxes and flow data. Now all the data is in one place and anyone can interact with it,” Director of the Army’s Network Cross Functional Team Gen. Patrick Ellis told reporters at the Pentagon today.
“Before PCC 6, we’re going to scale it [the integrated data layer] up to an entire division, so division headquarters, division enablers, multiple brigades,” he said. “What we found is the physical presence of everyone in one location, running this with a real unit, that’s given us the quality feedback that we need. And we’re going to make a project product that’s very useful to the Army.”
As the integrated data layer gets brought up to the division level, this will allow the layer to become accessible by multiple divisions at once since it is accessible over the cloud, Alex Miller, chief technology officer to Army Chief Gen. Randy George, told reporters.
“I’m confident that when the first division gets the core software and data pieces of this because they’ll be cloud based, multiple divisions will be able to log in at the same time,” he said. “So it will not just be a vertical stove piped deployment. So this year, the chief and the secretary will charter us, get a division and a quarter squared away. As soon as that’s live, other units will give it a login.”
Multiple divisions being able to log in to the integrated data layer at once will speed up the deployment of NGC2 across the entire force, Miller said. This, in turn, makes it difficult to put a timeline on when NGC2 will be fully deployed, he said. However, Ellis said the integrated data layer portion is moving along “really quickly” compared to how long the service’s usual processes take.
“As the integrated data layer goes live, it intends for anyone to be able to access it through their government system. So a division that’s not scheduled to get Next Gen C2, the full stack approach, would still be able to access that very, very early, if that’s something that they want to do,” Ellis said. “We’re excited about that, because we think that’s also going to help us accelerate the growth of this across the United States Army.”
Ellis said that the service began working on the integrated data layer at PCC4 last spring, but it was merely a “proof of concept” then. After PCC5 about three weeks ago, this proof of concept turned into a “proof of principle.” (Source: Defense News Early Bird/Breaking Defense.com)
31 Mar 25. DEEPX, a company specializing in on-device AI semiconductors, announced that its “Early Engagement Customer Program” (EECP)—ran over the past year in preparation for the mid-year mass-production launch of its first product—has received more than 300 customer validation requests worldwide for its DX-M1 prototype. This milestone reflects strong global interest in the upcoming mid-year release of DEEPX’s first mass-produced chip, the “DX-M1.” Through the program, the company has confirmed surging demand for on-device AI technology across a broad range of industries. Since last year, DEEPX has participated in over 20 global events to promote its prototype products and expand its international business footprint. The program specifically targeted companies requiring AI semiconductors—including those in surveillance systems, smart mobility, robotics, factory automation, and camera systems—by providing MPW (Multi-Project Wafer) based prototypes and technical support. By showcasing prototype capabilities in real-world environments, DEEPX proactively collected industry feedback and swiftly pinpointed areas needing further refinement. These efforts went well beyond simple readiness for mass production. They delivered valuable insights into each industry’s requirements and emerging market trends, while also securing diverse use cases from a wide spectrum of customers. DEEPX noted that the data and feedback gathered through this program has been instrumental in boosting both the technical robustness of the DX-M1, scheduled for release in mid-year, and its user convenience. DEEPX has also highlighted its technical strengths at leading industry events worldwide. By tailoring its response to specific technical needs—well before mass production—the company has garnered multiple awards from international organizations. Notably, DEEPX secured three innovation awards at CES 2024 for its original technologies, and at COMPUTEX Taipei, one of the largest AI semiconductor tradeshows, it won a startup terrace award in a competition against more than 400 companies. At this year’s CES, the Consumer Technology Association (CTA) even named DEEPX a “must-visit company,” drawing over 16,000 booth visitors—an all-time high. Additionally, DEEPX was recognized as the “2024 Company of the Year – In the Global Artificial Intelligence Chip Industry” by market research firm Frost & Sullivan, and the DX-M1 was named “the 2024 Product of the Year” by global IT publication EETimes. These accolades highlight DEEPX’s strong technological foundation and have heightened expectations for robust worldwide sales as soon as mass production officially launches mid-year. According to market research firm Omdia, the global AI chip market is set to reach approximately USD 243 bn by 2028, propelled by an emerging market of around USD 69 bn in sectors such as surveillance systems, smart mobility, and robotics. Recognizing these opportunities, DEEPX is expanding global partnerships in key regions including the United States, Taiwan, and Europe, continuously strengthening its product competitiveness through close collaboration with potential customers.
DEEPX’s CEO Lokwon Kim stated, “Over the past year, more than 300 companies worldwide have carried out customer validations with us, underscoring the rapid spread of on-device AI technology. With the official mid-year launch of the DX-M1, we aim to address market needs head-on and firmly establish DEEPX as a foremost global player in the on-device AI industry.”
27 Mar 25. Vantiq, C4i Systems unveil AI-powered solution for ACE operations. The VANGUARD AIX solution integrates Vantiq’s real-time intelligence platform with C4i’s AIX. Vantiq has joined forces with C4i Systems to introduce VANGUARD AIX, a real-time, AI-powered advanced solution for defence, emergency response, and national security operations, achieving a fully operational Technology Readiness Level 9 status. The VANGUARD AIX solution integrates Vantiq’s real-time intelligence platform with C4i’s AI Accelerator (AIX) to provide adaptive, mission-ready AI with a large language model. It is poised to deliver faster and more accurate responses for defence and first responder teams, aligning with the needs of today’s agile combat employment (ACE) operations.
Vantiq CEO Marty Sprinzen said: “AI for defence and security can’t just crunch data—it has to think, adapt and act quickly at machine speed, in a format that is easy to use in critical situations. Power and agility have never mattered more. VANGUARD AIX isn’t just an upgrade—it redefines how AI drives real-time decision-making in high-stake environments.”
This joint offering is designed to operate effectively in contested, low-communication, and high-risk environments such as dispersed headquarters, isolated command posts, and more. It is engineered to function across various command levels and agencies, offering the necessary Agentic AI and computational power to counter AI-equipped adversaries within the command, control, communications, computers, intelligence, surveillance, and reconnaissance system.
VANGUARD AIX’s advanced computing capabilities are expected to allow for automated threat detection and scalable situational awareness in real time.
C4i Systems Martyn Dove said: “This is about giving operators the confidence to act decisively, no matter the circumstances.
“By combining the strengths of our lightweight and ruggedised edge solutions with Vantiq’s advanced agentic AI platform, we’re equipping teams with the tools they need to navigate complex situations with speed and precision.”
The companies note that the system can be deployed in less than five minutes. In February 2025, Vantiq and NTT Data announced an enhanced collaboration to integrate AI into NTT Data’s disaster coordination platform, D-Resilio. (Source: army-technology.com)
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Oxley Group Ltd
Oxley offer a range of Military Marine NVG friendly LED lighting that includes navigation lights and controls, flight deck landing lights and interior compartment lighting. Our lighting products are used by Navies around the world including our own Royal Navy on UK Aircraft Carriers, Canadian Frigates, Swedish Submarines, Australian Surface vessels and Submarines, on board French Naval Carriers and in Naval Gun Turrets.
https://oxleydevelopments.cmail20.com/t/t-l-cdhkulk-yujhutkljd-r/
The technology is extremely energy efficient and built robustly, with proven long life. The lighting is NVG friendly, dimmable and programmable to allow for operations with aircraft pilots using military night vision goggles. They offer superior design giving high reliability for the most demanding environments with high sealing and the ability to meet the most stringent EMC standards.
https://oxleydevelopments.cmail20.com/t/t-l-cdhkulk-yujhutkljd-y/
Oxley are proud to say that we are working in partnership with SeaKing to enable a control panel to be offered with our LED Navigation Lighting. All of Oxley navigation lights have been specifically developed for vessels over 50 metres.
Contact Marcus Goad on 07850 917 263 for more information or to arrange samples.
Oxley specialises in the design and manufacture of advanced electronic and electro-optic components and systems for air, land and sea applications within the military sector. Established in 1942, Oxley has manufacturing facilities in the UK and USA and enjoys representation worldwide. The company’s products include night vision and LED lighting, data capture systems and electronic components. Oxley has pioneered the development of night vision compatible lighting. It offers a total package incorporating optical filters, equipment modification, cockpit and external lighting along with fleet wide upgrade services including engineering, installation, support, maintenance and training. The company’s long experience of manufacturing night vision lighting and LED indicators, coupled with advances in LED technology, has enabled it to develop LED solutions to replace incandescent and fluorescent lighting in existing applications as well as becoming the lighting option of choice in new applications such as portable military hospitals, UAV control stations and communication shelters.
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