Researchers on the Johns Hopkins Utilized Physics Laboratory (APL) are working with US Naval Sea Programs Command (NAVSEA) to advance laser powder mattress fusion for naval use. By intently managing course of parameters, APL goals to reveal that the know-how can constantly produce high-quality supplies appropriate for mission-critical parts.
Evaluating Reliability
Metallic AM has lengthy been met with skepticism attributable to considerations over porosity, mechanical inconsistency, and restricted reproducibility, defined Michael Presley, an additive manufacturing engineer in APL’s Analysis and Exploratory Growth Departmen. APL-led analysis seeks to deal with these points. One examine confirmed that optimizing course of parameters can get rid of porosity. One other demonstrated that materials consistency is feasible throughout a number of distributors. A 3rd confirmed that 3D printed components can match or exceed the sturdiness of historically manufactured parts.
Presley defined that these findings carry implications for NAVSEA because it evaluates the long-term viability of AM parts. “The anticipated service lifetime of a Virginia-class submarine is 33 years. NAVSEA should have confidence within the lifespan of additively constructed parts in comparison with these manufactured with conventional processes,” mentioned Eddie Gienger, who’s concerned within the analysis.
Guaranteeing Cross-Vendor Consistency
Scaling manufacturing requires greater than high quality: it requires repeatability throughout totally different suppliers. As NAVSEA’s technical lead for AM, Justin Rettaliata, defined, “We don’t simply want additive manufacturing to work — it wants it to work predictably. To scale up, we’d like a mature industrial base that may produce additively manufactured components at constant high quality ranges throughout distributors and environments.”
To assist that imaginative and prescient, APL has investigated how variability in uncooked supplies, machine settings, and processing situations have an effect on last properties. These insights led to new qualification strategies now built-in into NAVSEA’s manufacturing tips and certification requirements, slicing machine certification necessities by over 60% whereas preserving reliability. “It was about refining what actually issues,” mentioned Michael Presley. “As a substitute of requiring 300 take a look at samples and thousands and thousands of {dollars} in qualification prices, we helped streamline the method into one thing sensible but strong.”
APL additionally helps operational implementation of AM. In a single occasion, when a element on an amphibious Navy ship failed and no substitute was accessible, APL and the crew reverse-engineered the half and produced a brand new one utilizing wire-laser directed power deposition—all inside 5 days. Conventional procurement may have taken six months to 2 years. “That’s what success appears like,” mentioned James Borghardt, program supervisor for Maritime Expeditionary Logistics at APL. “Decreasing logistics delay time from months to days is a game-changer for operational availability.”
Trying Forward
Whereas additive manufacturing has demonstrated its worth in upkeep and fast repairs, its broader potential lies in being built-in into the design of future mission-critical techniques. Attaining this shift would require elevated confidence within the know-how’s consistency and long-term efficiency. “Success means a world the place we’re leveraging additive manufacturing not only for disaster fixes however for major design and development,” Rettaliata mentioned. “We’re not fairly there but, however our work with APL is getting us nearer day by day.”
Increasing the Navy’s Additive Manufacturing Ecosystem
The U.S. Navy’s curiosity in metallic additive manufacturing extends past analysis partnerships. In 2025, Australian large-format Wire Arc Additive Manufacturing (WAAM) specialist AML3D delivered 3D printed prototype tailpiece parts for the US Navy’s Virginia Class nuclear submarine program as a part of the trilateral AUKUS partnership. The Copper-Nickel parts, valued at roughly A$156,000, will endure testing earlier than being put in on a Virginia-Class nuclear submarine for in-service trials later this yr. AML3D manufactured these submarine components in lower than 5 weeks, a major enchancment over the 17-month lead time required by standard manufacturing strategies.
The corporate asserts that its metallic additive manufacturing know-how is essential to constructing a robust trilateral AUKUS provide chain in partnership with Australia’s allies, the US, and the UK.
In 2024, the United States Navy leveraged metallic and polymer 3D printers throughout the Rim of the Pacific (RIMPAC) train in Hawaii. Among the many deployed applied sciences had been a 3D chilly spray system from Australian 3D printer producer SPEE3D and Snowbird Applied sciences’ SAMM Tech hybrid DED manufacturing system. These trials had been designed to guage how additive techniques can shorten half supply timelines from days to hours, utilizing a complete “cradle-to-grave” logistics method to reinforce operational readiness.
Be a part of our Additive Manufacturing Benefit (AMAA) occasion on July tenth, the place AM leaders from Aerospace, House, and Protection come collectively to share mission-critical insights. On-line and free to attend. Safe your spot now.
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Featured picture reveals A US Navy submarine. Photograph by way of the Naval Sea Programs Command (NAVSEA).
