3D printing technology is regarded by the U.S. Department of Defense as a key technology for defense logistics support due to its advantages of rapid manufacturing of complex parts, reduction of manufacturing time and cost, and improvement of material utilization. Recently, the U.S. Department of Defense and other government agencies have promoted the application of 3D printing technology in the manufacture of spare parts, customized equipment, rapid deployment and battlefield repair, and have carried out a number of cooperation with private enterprises and universities to solve the problems faced by 3D printing technology in practical applications. It is expected that with the continuous development of 3D printing technology and related technologies, the application scope of this technology in the field of national defense will be further expanded, and it is expected to play a more important role in enhancing national defense capabilities.
1. 3D printing technology gives new capabilities to the field of national defense
As a cutting-edge technology that can change the R&D, production and maintenance mode of weapons and equipment, 3D printing technology has attracted the attention of the U.S. defense department. According to a report by AM Research, the U.S. Department of Defense's direct spending on 3D printing technology will be about $500 million in 2024 and will continue to grow at a compound annual growth rate of 23%, and is expected to reach $1.5 billion by 2030. This huge increase in investment underscores the strategic importance of 3D printing technology for the defense sector. Specifically, 3D printing technology can give new capabilities to the defense field in the following aspects:
First, it is necessary to realize the rapid manufacture of weapons and equipment and improve the speed of response. 3D printing technology can produce complex weapons and equipment and parts in a few hours, which greatly improves efficiency compared with traditional manufacturing methods, thereby improving the supply capacity of weapons and equipment, shortening the downtime of damaged weapons and equipment, and better matching the needs of rapid deployment and repair of weapons and equipment in military operations.
The second is customizable production. 3D printing technology allows for the on-demand manufacturing of personalized and customized parts, tools and equipment, without the need for large-scale production lines and inventory, and can meet the various special customization needs of high-end weapons and equipment, with high adaptability and flexibility.
The third is to reduce the logistics burden and reduce the logistics cost. By utilizing mobile 3D printing equipment for locally distributed production on the front line or in remote areas, the military can reduce its reliance on long-distance transportation and large-scale warehousing, and reduce logistics costs. At the same time, through local distributed production, the response speed of the army can be improved, and the risk of supply lines being detected and attacked can be reduced.
Fourth, improve the efficiency of resource utilization. Some weapons and equipment use expensive raw materials, and the use of 3D printing technology can reduce the consumables for complex structural parts. At the same time, in the manufacture of small-batch weapons and equipment, 3D printing technology can be used to directly carry out modeling and printing, without the need to manufacture molds, which reduces the overall investment.
Second, the U.S. defense department attaches great importance to 3D printing technology
For a long time, the U.S. Department of Defense and the military have regarded 3D printing technology as a strategic priority technology and attached great importance to it. In January 2021, the U.S. Department of Defense released the first "Department of Defense Additive Manufacturing Strategy" report, which regards 3D printing as a powerful tool to achieve defense system innovation and modernization and support combat readiness, and is committed to making 3D printing a widely used mainstream manufacturing technology. The report clarifies the vision, strategic goals and priorities for the future development of 3D printing. In order to further promote the use of 3D printing technology in the Department of Defense, in June 2021, the Office of the Under Secretary of Defense for Research and Engineering issued the Department of Defense 5000.93 Directive, which provides general guidance on the implementation and application of 3D printing technology in the Department of Defense to formulate policies, clarify responsibilities, and refine procedures. In May 2022, President Biden announced the launch of an additive manufacturing initiative called AM Forward, which aims to mobilize national efforts to support small and medium-sized enterprises to develop 3D printing technology and related technologies, as well as strengthen the manufacturing workforce and domestic supply chain through 3D printing technology. The first participants in the program include General Electric Aviation, Raytheon, Siemens Energy, Lockheed Martin and Honeywell. In February 2023, Matt Sermon, executive director of the U.S. Navy's Strategic Submarine Program Executive Office, said that the future of military shipbuilding depends on metal 3D printing technology, and the U.S. Navy will continue to increase the deployment of 3D printing technology. In October 2023, U.S. Army Chief of Staff Gen. Randy George said the U.S. Army wants to improve logistics and readiness through advanced manufacturing technologies such as 3D printing and other innovative initiatives. In addition, the U.S. Marine Corps plans to move from polymer-printed parts to full-metal printing by 2025.
3. Measures taken by the United States to promote the application of 3D printing technology in the field of national defense
(1) Establish a comprehensive repository of large-scale 3D printable parts files to achieve an efficient parts procurement process
In December 2023, the U.S. Defense Logistics Agency (DLA) partnered with BMNT, an innovation consulting firm, to create a 3D printable parts file repository to further advance the full application of 3D printing technology in the field of defense and security. DLA streamlines the parts procurement process by using other Authorization to Trade (OTA) contracts, enabling DLA to respond more quickly to the Department of Defense's demand for parts. This process change has reduced the time required to procure parts from the traditional three-plus months to less than two weeks, further improving the Department of Defense's resilience. In addition, DLA has expanded its supplier base by integrating thousands of U.S. manufacturers into the defense supply chain. This expansion not only increases the resilience of supply chains, but also gives the Department of Defense more options and flexibility to meet changing demands.
(2) Strengthen the deployment of 3D printing systems and reduce costs
The U.S. Navy has successfully deployed multiple 3D printing systems on different types of ships and submarines. The deployment of such diverse systems is expected to reduce the U.S. Navy's reliance on traditional supply chains and improve maritime logistics capabilities, thereby increasing the readiness of ships and systems. In January 2023, the U.S. Navy successfully deployed an additive-subtractive hybrid manufacturing system aboard the amphibious assault ship Bataan. The system's ability to 3D print 316L grade stainless steel parts provides the U.S. Navy with technical support for the manufacture of industrial-grade ship-specific metal parts at a low cost. Soon after, the crew of the Bataan used the manufacturing system on board for the first time to manufacture metal parts. The whole process took only five days, saving the US Navy about $400,000. In February of the same year, the U.S. Navy installed a new "Markforged X7" 3D printer on the nuclear submarine USS New Hampshire (SSN 778) to repair various equipment such as pipeline leaks and new electrical equipment enclosures in real time. The deployment of 3D printing systems has enabled the previously difficult to obtain individual parts to be manufactured directly on board, replacing the previously costly and time-consuming replacement of parts.
In addition, the U.S. military has strengthened the practical application capabilities of 3D printing systems in the fields of medical care and construction support. For example, in July 2023, the Marine Corps successfully 3D printed a medical mold during the high-speed flight of the MV-22B Osprey transport aircraft during a comprehensive training exercise, breaking through the limitations of traditional manufacturing on the clean room environment and demonstrating the potential advantages of 3D printing technology in improving supply chain resilience and the combat readiness of expeditionary forces. In November 2023, the U.S. Army Corps of Engineers conducted an explosion test of a concrete structure built using 3D printing technology, proving its performance and durability in explosive conditions.
(3) Provide multiple subsidies and launch R&D project solicitation
Through multi-agency cooperation, funding multiple projects, and conducting research in different fields, the United States actively promotes the research and development and application of 3D printing technology in defense manufacturing, providing all-round support for improving manufacturing efficiency, reducing costs, and solving problems in specific fields.
In April 2023, the U.S. Department of Defense Lightweight Manufacturing Innovation Agency (LIFT) and Michigan Technological University launched a number of 3D printing R&D projects, including metal powder atomization systems, customized metal alloys, and the development of a roadmap for the application of metal alloys in the field of hyperhypersonics, accelerating the research and development of materials and processes for 3D printing military applications. In October of the same year, the Air Force Research Laboratory-funded "Demonstration of New Methods for Efficient Identification/Requalification of Additive Manufacturing Processes" program revealed six projects dedicated to developing qualified 3D printing processes while employing advanced technologies such as machine learning for efficient monitoring. In November 2023, the U.S. Defense Manufacturing and Processing Center and American makes announced funding for the "Improving Manufacturing Productivity through Additive Manufacturing Capabilities and Techno-Economic Analysis" (IMPACT) call for funding from the Office of the U.S. Undersecretary of Defense for Research and Engineering and the Air Force Research Laboratory for a total of $11.7 million. This funding further underscores the strategic importance of the Department of Defense to 3D printing in increasing productivity and addressing manufacturing challenges. In April 2024, the U.S. Air Force Research Laboratory (AFRL) signed an $8.7 million contract with Relativity Space to develop real-time defect detection technology for large-area 3D printing using the latter's 3D printing technology to support the development of metal 3D printing in the U.S. Air Force.
(4) Strengthen enterprise cooperation and improve supply chain security
The United States continues to work closely with its own companies to develop new technologies that can quickly leverage innovations to meet the military's requirements. In April 2023, the U.S. Air Force partnered with Amentum to modernize its logistics system through 3D scanning and 3D printing to provide commercial procurement solutions to facilitate service to foreign military sales customers. In September 2023, ATI was awarded a contract by the relevant agencies of the U.S. Navy's nuclear propulsion program to establish an advanced 3D printing facility in 2024 to improve the capacity of 3D printing parts and accelerate ship construction. This cooperation will support the latest naval equipment such as the Virginia-class nuclear submarine and the Ford-class aircraft carrier to enter service with the U.S. Navy. In the same month, Branch Technologies was awarded a $1.13 million contract from the U.S. Air Force Research Laboratory and the Office of the Air Force Technology Accelerator (AFWERX) to provide innovative solutions for military buildings and improve the performance of Air Force buildings and comprehensive force support capabilities through its unique cellular manufacturing 3D printing technology.
At the same time, the United States has strengthened cooperation with leading international companies to obtain the latest 3D printing technology and further promote the rapid development of its own 3D printing technology. In partnership with Australia's SPEE3D, the U.S. Navy is the first to use cold spray 3D printing technology for metal, enabling fast, reliable, and easy-to-deploy submarine component manufacturing. In addition, in September 2023, AML 3D, an Australian metal additive manufacturing company, signed a $230,000 contract for the characterization and testing of new alloys with the U.S. Department of Defense-backed BlueForge Alliance to develop and test 3D-printed copper-nickel parts in support of the U.S. Navy's submarine program. In November 2023, U.S. defense manufacturing company Cogitic purchased a ARCEMY3D printing system from Australia's AML3D, which will supply metal 3D printed parts to the U.S. Navy's submarine industrial base. The deepening of the cooperation between the two parties also demonstrates the growing demand for 3D technology in the supply chain of the U.S. Navy submarine industry.
(5) Strengthen personnel training and talent reserves
To better respond to the growing demand for 3D printing technology from the U.S. Department of Defense, the U.S. government ensures that the military has the expertise and knowledge to respond to the changing technological landscape through a variety of training and talent reserving programs. As early as 2017, the United States established the national 3D printing training program ACADEM and promoted it throughout the military, aiming to make engineers, technicians and maintenance personnel of all branches of the military have sufficient operating experience and skills to be proficient in the use of various 3D printing systems. At the same time, the U.S. military promotes research and education in 3D printing technology-related majors through cooperation with academic institutions and research centers, including the establishment of specialized research programs, scholarship programs, and cooperation with military academies. In addition, the U.S. Department of Defense encourages knowledge sharing and experience transfer within the military, and ensures that best practices in 3D printing technology are widely disseminated by developing policies and procedures. This internal communication not only helps to improve the overall level of technology, but also fosters collaborative efforts for innovation and problem solving.
IV. Concluding remarks
The United States continues to promote the application and development of 3D printing technology in the field of national defense, which has had a positive impact on the US army, navy, air force and space forces and their logistics support systems. The strategic layout of the U.S. Department of Defense and its emphasis on innovative technology make 3D printing not only an important force to promote technological progress, but also provide important technical support for coping with future military challenges. It is expected that with the continuous progress and breakthrough of new 3D printing materials, as well as the continuous integration of new technologies such as artificial intelligence and robotics with 3D printing technology, the weapons and equipment parts manufactured by 3D printing technology will have better performance, and the automation and intelligence level of 3D printing will be further improved, so as to play a more important role in the field of national defense.
About the Author
Dong Rong, Research Office No. 5, International Institute of Technology and Economics, Development Research Center of the State Council
Research interests: cutting-edge technology tracking and industrial and policy research in the field of advanced manufacturing
Editor丨Zheng Shi
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