Aerospace and protection now rank among the many largest and most dear sectors adopting additive manufacturing.
Ongoing worldwide provide chain disruptions, rising geopolitical tensions, and international conflicts threaten entry to important gear and elements very important for nationwide safety. In response, protection businesses are turning to 3D printing to chop lead occasions, localize manufacturing, restore gear, and restock depleted inventories.
This rising concentrate on 3D printing for protection was evident at RAPID + TCT 2025, which co-located with the eighth version of SME’s AeroDef Manufacturing 2025 expo. A big part of the present ground at Detroit’s Huntington Place was devoted to key exhibitors throughout the army expertise ecosystem. This included warmth exchanger producer Conflux Expertise, aerospace 3D printing agency Hyphen Improvements, and US protection manufacturing accelerator LIFT.
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AeroDef additionally featured a stacked convention monitor. Skilled-led shows and panels supplied insights into the worth, alternatives, and challenges going through the protection industrial base.
Main Normal Michael Lalor of the U.S. Military highlighted 3D printing’s function in sustaining 70% of the infantry’s fight stock. He additionally emphasised its significance for constructing an “arsenal of democracy” in Detroit.
RHH Advisory’s Tali Rosman recognized 3D printing’s potential to extend the tempo of American manufacturing. That is notably important on condition that China’s shipbuilding capability is at the moment 350 occasions higher than that of america. A BlueForge Alliance-led panel mentioned the best way to speed up manufacturing within the U.S. Navy’s industrial base, highlighting the worth and challenges surrounding 3D printing adoption.
Elsewhere, Dr. Invoice Anderson highlighted the cybersecurity threats that malicious overseas actors pose to the digital ecosystem of additive manufacturing. Boeing’s Daniel Braley was additionally on the agenda. He highlighted vulnerabilities within the provide chain for important minerals and supplies, citing the “menace of the U.S. going to full-scale warfare in a single to 2 years.” As geopolitical tensions rise and international provide chains constrict, all audio system broadly agreed that 3D printing will turn into a important strategic pillar in safeguarding the West’s protection industrial base.
Main Normal Michael Lalor: Superior manufacturing at U.S. Military TACOM
Main Normal Michael B. Lalor, Commanding Normal of U.S. Military Tank-automotive and Armaments Command (TACOM), opened the AeroDef convention with a welcome handle. Headquartered at Detroit Arsenal, the Command manages 70% of the U.S. Military’s floor fight stock. “If a soldier drives it, shoots it, or wears it, we maintain it,” Lalor defined.
TACOM oversees a $30 billion annual funds and manages over 3,500 weapon programs. In accordance with the previous M1A1 Tank Platoon Chief, these embrace all the things from Abrams and Bradley tanks to eight-wheeled Stryker armored combating automobiles and artillery programs. TACOM maintains a world presence. At any given time, about 350 personnel throughout 70 “flyaway groups” function abroad, supporting provide chain operations for items within the area.
Collaboration with trade companions is important for TACOM’s operations. He famous that technological evolution and provide chain complexities demand new ranges of collaboration that transcend “worldwide and conventional boundaries.” Lalor added that TACOM is main the U.S. Military in superior manufacturing. 3D printing is being leveraged to manufacture custom-made elements on demand, decreasing reliance on prolonged lead occasions. TACOM’s Main Normal highlighted that the Command has seen “superb outcomes” via this adoption.
Over the previous yr, TACOM has developed its Battle Injury Restore and Fabrication Program (BDRF). The initiative leverages additive manufacturing to supply non permanent alternative elements for broken army automobiles. This reduces downtime and will increase operational readiness, permitting important warfighting gear to be returned to the battlefield in much less time.
Over 40,000 car elements have been assessed for additive manufacturability in collaboration with the U.S. Military DEVCOM Floor Car Techniques Heart and TACOM Built-in Logistics Assist Heart. From this, TACOM’s Rock Island Arsenal – Joint Manufacturing and Expertise Heart in Illinois has 3D printed greater than 600 3D CAD fashions.
In accordance with Lalor, these efforts are very important to relieving the substantial stress on America’s few remaining foundries. The U.S. Military’s solely operational foundry at Rock Island has seen its workload quadruple over the previous 18 months amid a dearth of home castings and forgings capabilities.
Lalor revealed that Rock Hill Arsenal’s additive manufacturing applied sciences will probably be ASTM 9100 compliant by June 2025, when it’ll ramp up manufacturing of aerospace and aviation-certified elements. “There are gaps to shut, and that arsenal is a part of the answer,” he added.
The worth of 3D printing for protection
In a separate presentation, Tali Rosman, a Enterprise and M&A advisor at RHH Advisory and former Elem Additive CEO, shared her perspective on the protection alternative for 3D printing.
Rosman emphasised the U.S. Division of Protection’s (DOD) rising adoption of additive manufacturing, suggesting that the Pentagon is “arguably the biggest consumer” of additive manufacturing primarily based on {dollars} spent. Nonetheless, this adoption comes amid a difficult level for the Pentagon. In accordance with Rosman, “China is outpacing the U.S. when it comes to manufacturing.” Notably, she highlighted that China’s shipbuilding capability is 350 occasions that of america.
Amid this menace, the DOD is adopting additive manufacturing “in earnest” to safe the U.S. protection provide chain. Whereas it may possibly take years to construct typical manufacturing vegetation, some 3D printing applied sciences can begin fabricating elements in weeks. In immediately’s “unstable and unsure world,” that velocity makes the expertise particularly interesting.
Rosman highlighted expeditionary manufacturing as one key software for 3D printing. She emphasised that battle in Ukraine has “paved the way in which” for its distant deployment. Ukrainian troopers are leveraging metallic additive manufacturing, together with chilly spray 3D printers from SPEE3D, to extend gear uptime and localize important provide chains.
The U.S. Navy has additionally put in 3D printers on warships to conduct repairs and fabricate alternative elements on the level of want. Final yr, SPEE3D’s XSPEE3D and Snowbird Applied sciences’ SAMM Tech hybrid DED manufacturing system have been deployed in the course of the Rim of the Pacific (RIMPAC) train in Hawaii. Throughout the trial, Navy personnel sought to cut back the supply time of important elements from days to hours.
Moreover, Rosman highlighted elevated DOD funding to restock its depleted missile arsenals utilizing 3D printing. She pointed to Albuquerque-based aerospace agency X-Bow Launch Techniques, which lately acquired an extra $9.85 million from the DOD to advance analysis into 3D printed strong rocket motors (SRMs). This new capital sees the corporate’s present DOD contract worth rise to $28.67 million, whereas its complete U.S. protection funding has exceeded $97 million.
Equally, the Pentagon has backed Ursa Main to 3D print missile SRMs. Final December, the Colorado-based agency accomplished profitable flight testing for the U.S. Military. Daniel Jablonsky, Ursa Main’s CEO, claimed that the corporate’s Lynx 3D printing expertise unlocked “unprecedented timelines,” with practically 300 SRM static take a look at fires accomplished in 2024.
Wanting forward, Rosman anticipates that 3D printing will play an growing function for a lot of of America’s allies. European international locations are anticipated to ramp up protection funding, following the Trump administration’s name for elevated safety spending amongst NATO members. For example, Germany’s protection spending may develop to three% of GDP by 2027, doubtlessly exceeding 3.5% after that, in line with Goldman Sachs analysis.
Rosman believes a “disproportionate” quantity of Europe’s funding will probably be “flowing into the additive manufacturing sector” within the coming years. Certainly, the UK lately outlined plans to speed up 3D printing for protection. The Ministry of Protection (MOD) goals to extend funding to incentivise adoption, adapt insurance policies to take away boundaries, and more and more combine additive manufacturing into the protection provide chain.
Additive manufacturing bolsters the US Navy’s industrial base
The function of additive manufacturing within the U.S. submarine industrial base (SIB) can be rising. Main this effort is BlueForge Alliance (BFA), a nonprofit protection integrator. Headquartered in Bryan, Texas, BFA coordinates manufacturing, recruitment, and expertise integration to assist the U.S. Navy’s manufacturing provide chain.
Throughout a panel dialogue, Tim Shinbara, BFA’s Chief Technique Officer, sat down with James Hockey, Director of metallic 3D printing service supplier Incodema3D, and Greg Mallon, Chief Technique Officer of engineering and manufacturing agency GSE Dynamics. Incodema3D and GSE Dynamics are among the many roughly 16,000 corporations working in America’s ship and submarine manufacturing sector.
Mallon recognized workforce challenges as stunting the expansion of America’s maritime industrial base. He famous that over the previous 30 years, the U.S. has shifted from a goods-based financial system to at least one pushed by digital and repair industries. The outcome? A shrunken manufacturing workforce, down from 3 million to only over 1,000,000 staff. “That has left the protection industrial base very atrophied,” Mallon added.
Additive manufacturing corporations, like Incodema3D, are not any much less affected. “Our largest drawback remains to be expertise,” agreed Hockey. “We will’t rent folks quick sufficient.” The 27-year 3D printing veteran defined that Incodema3D must be rising 25% yearly “simply to maintain up with the scaling we’ve already accomplished.” Nonetheless, the corporate, which operates out of Freeville, New York, has solely grown 30% since its founding in 2013.
BluForge Alliance is working to alleviate these shortfalls via buildsubmarines.com, an internet site that connects staff with employers within the submarine industrial base. In accordance with Shinbara, the recruitment instrument presents a low-cost and efficient resolution to workforce challenges. “It’s solely eight cents for somebody to use, and we discovered it’s about $700 per individual to be employed,” he defined.
Adoption additionally stays a core problem inside maritime manufacturing. Particularly, Hockey recognized the necessity for purchasers to embrace design for additive manufacturing (DfAM) and perceive the place the worth lies.
He highlighted a typical subject with additive manufacturing: the belief that it’s all the time the sooner resolution. Particularly, clients are more and more requesting low-volume casting for legacy elements. Hockey defined that these functions provide little worth until the design contains novel geometries or options enabled by 3D printing.
For Mallon, the roadblocks to adoption transcend the equipment, citing “a scarcity of enthusiasm to undertake that new expertise.” He highlighted a “resistance to alter” amongst skilled staff, typically because of job safety issues or consolation with legacy programs. Nonetheless, there may be stronger enthusiasm for 3D printing amongst youthful staff, who “embrace the expertise a lot sooner.”
Trying to the way forward for maritime manufacturing, Mallon believes hope lies in predictable protection applications and automation. “While you take a look at the Navy’s 30-year shipbuilding plan, annually it adjustments,” he mentioned. “It’s onerous to comply with.” Mallon believes elevated predictability would permit clients to comply with via on applications and prioritize execution. Furthermore, GSE Dynamics’ Chief Technique Officer believes elevated automation will enhance effectivity and velocity.
Hockey echoed this sentiment, highlighting his firm’s inside push for tighter integration between additive manufacturing and CNC machining. Hockey predicted that streamlined workflows will ease staffing pressures whereas additionally elevating the general ability degree of the workforce.
Shinbara, surveying the broader context from Washington, D.C., concluded with a hopeful notice. “The coverage, posture, and funding are beginning to align,” he mentioned. “It’s in all probability one of many few occasions exterior of World Conflict Two” that the U.S. has seen this degree of coverage and monetary momentum.
Cybersecurity threats and logistical challenges
Safety threats and provide chain challenges additionally jeopardize adoption and progress. Dr. Invoice Anderson, Principal Product Supervisor at Mattermost, underscored main cybersecurity issues. He pointed to the dangers tied to additive manufacturing’s increasing digital footprint.
Anderson opened his presentation with a stark warning: “The federal government is below assault from overseas adversaries.” He emphasised that authorities suppliers, contract producers, and OEMs face important threat.
The digital safety professional noticed that even producers removed from the entrance traces are below menace, warning, “You’re being attacked now, you in all probability simply don’t realize it.” The College of Waterloo alumnus defined that, in wartime, the West’s adversaries could look to close down suppliers’ programs. This might have knock-on results, impacting the army and authorities’s capability to function.
In accordance with Anderson, about 70% of cyberattacks on the protection industrial base are dedicated by nation states. He pointed to China as a significant menace, notably Volt Hurricane, reportedly a Chinese language state-sponsored hacker group engaged in cyberespionage. In 2023, this superior persistent menace (APT) breached business and Navy networks close to Guam. Whereas the U.S. efficiently thwarted the intrusion, the assault may have severed communications throughout the Pacific. Such a functionality would carry critical strategic penalties, notably amid escalating tensions over Taiwan.
Safety threats additionally influence the provision of important supplies. Braley, a Technical Fellow at Boeing, described the worldwide provide chain as a “excellent storm.” He defined that intensifying threats from Russia, North Korea, China, and Iran have “severely affected” America’s capability to acquire uncooked supplies and manufactured elements.
Tightening U.S. and worldwide laws constrain the movement of supplies important to America’s protection manufacturing. In accordance with Braley, “the true subject for the aerospace trade” lies in latest amendments to the Nationwide Protection Authorization Act (NDAA), which introduce new import restrictions.
Braley famous that the majority titanium powder utilized in metallic 3D printing is sourced from China. Below the up to date NDAA, the DOD may very well be barred from procuring Chinese language titanium powder beginning in June 2026. The laws can even prohibit imports of key metal and metallic alloys, together with nickel, iron, cobalt, zirconium, and their derivatives.
Braley is particularly involved about magnesium, which he says has “hint parts in nearly all the things.” Since “the overwhelming majority of magnesium comes from China,” he warned that the restrictions will “drastically have an effect on nearly each product we make within the US.”
The way forward for 3D printing for protection
Regardless of these issues, additive manufacturing is quickly turning into a significant asset for protection functions. It presents worth in strengthening provide chains, enhancing fight capabilities, decreasing lead occasions, and replenishing depleted weapon stockpiles. The Pentagon has taken notice, committing important funding to scale home 3D printing capability and domesticate a resilient community of additive manufacturing suppliers.
Rosman highlighted the rising market alternative for 3D printing in protection, citing knowledge from Additive Manufacturing Analysis (AM Analysis). In its 2024 report, the New York-based agency projected that DOD spending on 3D printing will exceed $1 billion in 2025, up from $800 million final yr. U.S. funding is projected to rise steadily via the last decade, reaching $2.6 billion by 2030.
These findings align with the views shared by audio system in Detroit. As geopolitical tensions and safety issues intensify, 3D printing is poised to play a bigger function in strengthening international protection capabilities. Whereas Europe is anticipated to ramp up adoption within the coming years, america is already investing closely to safe a number one place within the additive manufacturing panorama. Whereas challenges persist, elevated collaboration between state and trade appears set to speed up additive manufacturing adoption inside America’s protection industrial base.
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Featured picture exhibits Main Normal Michael Lalor talking at AeroDef Manufacturing 2025. Picture by 3D Printing Business.
