Fifteen Applications Of Additive Manufacturing in The Field Of National Defense​

Additive manufacturing technology has always been widely used in many fields, including marine, aerospace and automotive, with its powerful functions. Of course, it is also increasingly being adopted by defense departments around the world. In fact, it is expected that by 2027, the value of the military 3D printing industry will reach 1.7 billion U.S. dollars.

Considering the demand for faster speed, lighter weight and lower cost of military products, it is undoubtedly the most appropriate to choose additive manufacturing technology to achieve these functions. Some cases of the application of 3D printing technology in the field of national defense in various countries around the world are listed. From these actual cases, we can further see the importance of this technology in national defense.

01

9-meter-long metal 3D printer

The U.S. military is convinced of the benefits of additive manufacturing, and in 2021 they have announced that they will build the world's largest metal 3D printer. The U.S. DEVCOM Army Ground Vehicle System Center is manufacturing this giant printer with the help of ASTRO America, Ingersoll Machine Tool, Siemens and the MELD Manufacturing Joint Manufacturing and Technology Center in Rock Island Arsenal. This printer will become part of the seamless body project, and the ultimate task is to print an integrated body for the chariot. It is reported that the project is expected to take about 14 months, and the final printer will be able to print metal parts 30 feet long, 20 feet wide, and 12 feet high (about 9 meters×6 meters×3.6 meters). Although we have no news in this regard recently, the project is likely to be completed in the near future.

02

3D printing runway

Another application in the military and national defense fields comes from ITAMCO (Indiana Technology and Manufacturing Company), which uses additive manufacturing to develop a runway for a military expedition airport. These runway mats are an important part of the Expeditionary Airport (EAF). Their function is to be implemented on weaker ground to allow military aircraft to land and take off. Before that, a portable runway made of aluminum sheet was used, but as it became obsolete, the army needed to find an innovative solution. The M290 3D printer of the German company EOS is used to make lighter and more durable models for the military equipment of the US Air Force.

03

ExOne and its military pod

In order to accelerate the development of a powerful and rugged 3D printing factory pod, ExOne participated in the implementation of this task after working with multiple partners. Specifically, it involves a1.6 million Defense Logistics Agency (DLA) contract. In this process, ExOne's Binderjet technology is used for military purposes because of its fast speed, flexible materials and ease of operation, which can well meet the key needs of the military. This 3D printer designed for the military is said to be able to spray adhesives and more than 20 kinds of metals, ceramics, and other powdered materials. In addition, it is said that the unique housing and other functions make it very suitable for military-grade products.

04

3D printing tools for the U.S. Navy

The U.S. Navy is also using additive manufacturing, and their Marine Corps has discovered the ability of 3D printing to develop new vehicle maintenance tools. The Marine Corps Systems Command works with supply battalions and industry partners to produce additive manufacturing fixtures for removing steering wheels from metal through 3D printing technology. This is a problem that often needs to be solved in the maintenance of naval vehicles. Additive manufacturing can help reduce maintenance and tool preparation time, and can reduce the actual waiting time for such parts to about 25 days.

05

Cooperation between the U.S. Army and the University of South Florida to develop light magnesium alloy

In terms of the reasons for 3D printing technology, in addition to regular cooperation with related companies, the U.S. Army is also cooperating with some universities. Recently, scientists at the University of Central Florida successfully 3D printed a magnesium alloy called WE43. It is reported that the development of this material by researchers is not a coincidence, but out of the needs of the military. American soldiers often need to be forced to carry extremely heavy bags and equipment, so it is very necessary to reduce their weight. However, with the help of WE43 and powder laser fusion technology, the US Army and the University of Central Florida may have found a solution.

06

3D printing the propeller of the ship

In recent years, the famous French company Naval Group has been using 3D printing technology to meet various needs. In January 2021, thanks to the WAAM (Wire Arc Additive Manufacturing) additive manufacturing process, NavalGroup has 3D printed the propeller. The propeller consists of five 200 kg blades and is then installed on the Andromeda, a mine detection ship. The team behind the project explained that by using 3D printing technology, they greatly reduced construction time and minimized the amount of materials used.

07

The Spanish Air Force upgraded its process through 3D printing

Additive manufacturing can help parts achieve high hardness, high strength and other excellent characteristics. Through internal fiber reinforcement, researchers have developed various tools and terminal parts that can withstand the harsh performance conditions required when the components are subjected to very large forces without any errors. In Madrid, the head of the Spanish Air Force helicopter workshop said that now they are trying to manufacture each part through additive manufacturing and avoid traditional manufacturing. These components include leak control measurement tools for helicopter landing gear or custom keys for helicopter main rotors.

08

General Lattice and its helmets designed for the U.S. Army

GeneralLattice, a 3D design software company, and the U.S. Army signed a contract to improve the impact absorption capacity of army combat helmets through 3D printing and advanced grid geometry. For this project, the company developed a set of predictive modeling tools to design and generate helmet materials. In order to improve the protection of soldiers on the battlefield and the possibility of survival after head impact, 3D printed materials will be tested in a real environment to verify the performance requirements of the development command soldier center.

09

Spare parts in combat armored vehicles

The Australian Army used the cold spraying 3D printing solution developed by SPEE3D to design more than a dozen spare parts for one of its armored vehicles. These components have passed many field use tests and certifications, improving the agility of the Australian Army. For example, the printed components include a wheel cover that took only 29 minutes to make, and the total cost is 100 Australian dollars. The machine used in this case is WarpSPEE3D, which has a printing volume of 1000 x 700 mm and a speed of 1 kg per minute. Through the introduction of additive manufacturing technology, the army can reduce the downtime of armored vehicles and thus better respond to emergencies.

10

U.S. Navy and Additive Manufacturing

Over the years, the U.S. Navy has been working on multiple additive manufacturing projects. The goal is to improve the agility and efficiency of the team performing tasks in the ocean, especially in the manufacture of spare parts. This is why the Naval Postgraduate School (NPS) invested in Xerox ElemX metal machines. They used this equipment to design spare parts and tools for submarines and ships, which allowed Xerox to have a shorter supply chain and manufacture customized components. NPS is not the only company to launch 3D printing projects in the maritime field. In fact, MatterHackers has signed a 5-year contract with the U.S. Navy to provide all the 3D equipment it needs, as well as training courses and maintenance.

11

Future energy projects

The Future Energy project from the UK works in the fields of research, explosive testing, new energetics manufacturing, explosion modeling, chemical synthesis, thermal characterization, and hazard testing. The goal of the project is to create new energy-containing materials and diagnostic methods to verify new materials. Additive manufacturing will be used to develop new explosive formulations, which provide potential users with many benefits, including reduced storage and transportation costs and improved performance. The cost can be precisely customized according to requirements and manufactured in a novel and complex design, which was previously unthinkable. The manufacturing process uses a LabRam resonance acoustic mixer, which uses sound energy instead of physical blades to mix materials, making the process safer.

12

Astro America develops 3D printed chariot body

The Applied Science and Technology Research Organization, also known as ASTRO America, has been selected by the U.S. Army for the seamless hull project. The program is supported by the Manufacturing Innovation Institute, which benefits from the U.S. Department of Defense, and is part of an effort to develop and deliver combat vehicle hull tools using 3D printing. They hope to reduce manufacturing time and reduce production costs, while reducing the weight of the vehicle and improving its performance and survivability.

13

3D printing barracks

ICON, a 3D construction company, is known for its projects involving the military. To this end, the Austin-based company collaborated with the Texas Department of Military Affairs, Logan Architecture, and Fort Structures to create the largest 3D printed structure in North America: the training camp at the Swift Camp Training Center in Bastrop, Texas. Using ICON's Vulcan building system, a robotic printer operated by a tablet computer that can use cement-based materials, the company and the military successfully built the first 3D-printed military camp for soldiers to live in. The final building includes a 3,800-square-foot building that can accommodate up to 72 soldiers or pilots and prepare for their next mission.

14

3D printing submarine hull

Over the years, the defense department has found ways to apply 3D printing in many fields-on the ground, in the air, and at sea. In fact, this latest project of the US military is exploring a relatively unknown area of 3D printing: the seabed. In 2017, Oak Ridge National Laboratory (ORNL) cooperated with the U.S. Navy's Disruptive Technology Laboratory for this new attempt, helping to create the first 3D-printed submarine hull in military history. By using ORNL's FDM large-area additive manufacturing (BAAM) technology, the team produced a 30-foot concept hull with 6 carbon fiber composite parts. Compared with traditional manufacturing methods, its production speed is faster and the cost is lower. Although it is still being tested, there are signs that more 3D-printed submarines will dive into the ocean soon in the future.

15

The University of Maine develops a logistics support ship for the U.S. Marine Corps

In March this year, the University of Maine (UMaine) 3D printed two new large-scale ships at its Advanced Structure and Composite Materials Center in Orono, one of which is said to be the largest additive manufacturing ship ever built. It is understood that the two prototype ships were developed for the United States Marine Corps, designed as logistics support ships, and will be tested for field use by the armed forces. The larger one can carry two 20-foot shipping containers, while the other can transport food, water and other supplies for the entire rifle squad for a period of three days. Both new ships are 3D printed with a multi-material mixture of polymer-based fiber-reinforced composite materials. According to UMaine, it was able to manufacture and assemble one of the ships in just one month. If traditional manufacturing methods are used, this process will take up to one year.