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In May 2022, the Biden Administration joined GE Aviation, Honeywell, In 2020, Icon, a Texas-based company special-
Lockheed Martin, Raytheon, and Siemens Energy to launch Additive izing in 3D-printing technology, used Vulcan,
Manufacturing Forward (AM Forward) to encourage the use of 3D a 9,500-pound, 46.5-foot-wide 3D printer, to
printing technologies in companies across the United States. The help the Marines transform a blank patch of
initiative, which is expected to have a positive impact on supply dirt, within three days, into a concrete bunker
chain resilience, involves the five companies purchasing additively for vehicles at Camp Pendleton, California. The
produced parts from smaller U.S.-based suppliers, training the work- next year, Icon worked with the Texas Military
ers of suppliers on new additive technologies, developing common, Department to 3D print a 3,800-square foot
and introducing certification for additive products. 72-soldier barracks at the Camp Swift Training
Center. The company is now using Vulcan to
build three, 5,700-square foot barracks at Fort
Showing the Way Bliss, Texas within the next 10 months. The bar-
The 3D printer onboard USS Essex is just one of the examples of racks will be the largest 3D printed buildings in
the extensive use of AM by the U.S. military. In recent years, differ- the western hemisphere, according to the U.S.
ent services have turned to 3D printing to produce spare parts for Army.
fighter jets, drones, and even barracks for remote outposts. The
Defence Logistics Agency (DLA) of the U.S. Department of Defence “Constructing facilities using this cutting-edge
(DoD) is developing a set of common standards and methods to technology saves labour costs, reduces planning
streamline 3D printing for the U.S. military. The DLA is also finetuning time, and increases the speed of construction
a programme that will facilitate remote inspection for 3D printed of future facilities,” says Army Lt. Gen. Doug
parts; this is expected to reduce the time required for inspection by Gabram, commander of U.S. Army Installation
a whopping 90 per cent. Management Command. “We are looking at
other ways to use this innovative technique for
The U.S. Army will get the world’s largest metal 3D printer, one big rapid construction of other types of facilities
enough to manufacture full-sized combat vehicles and small boats, beyond barracks.”
in the second half of 2023 as part of a US$45 million project. The
Jointless Hull project, which has Ingersoll Machine Tools as the main The U.S. Defence Department is also eyeing the
contractor, envisages the delivery of the 3D printer to the Rock Island benefits of using 3D printing to make hypersonic
Arsenal Joint Manufacturing and Technology Center in Illinois, where missiles more efficiently and quickly. In October
the Army’s Additive Manufacturing Center of Excellence is located. last year, the DoD sought prototype solutions for
One of the standout features of the Jointless Hull is that it can print its Growing Additive Manufacturing Maturity for
with multiple metals, including aluminum, steel, and titanium. Airbreathing Hypersonics (GAMMA-H) challenge.
The initiative is intended to find 3D printing
The U.S. Navy is one of the early birds when it comes to adopting techniques that can meet the high temperature
the technology. In 2017, the service used additive manufacturing and propulsion standards for hypersonic air-
to create submarine parts. In October 2022, it opened its Additive breathing systems, the technology that powers
Manufacturing Center of Excellence at the State of Virginia’s Center hypersonic weapons.
for Manufacturing Advancement on the campus of the Institute for
Advanced Learning and Research. In January last year, the U.S. Meanwhile, British company Babcock has man-
ufactured and fitted what are believed to be the
Naval Surface Warfare Center signed six new AM deals, with com- first 3D printed metal parts to be used across
panies as diverse as General Electric, Johns Hopkins APL, Lockheed the British Army’s active armored fleets. The
Martin RMS, Mercury Systems, ReLogic Research, and Charles Stark steel components were created and fitted onto
Draper Laboratory. The companies are working on developing proto- in-service fleets, Titan, and Trojan vehicles. The
type projects, using 3D printing technology, that focus on protecting company, which recently launched its technol-
military technologies from the enemy attacks. In November, the ogy partnership with Plymouth Science Park,
service made news by permanently installing a metal 3D printer has opened an innovation center focused on
aboard naval ship USS Bataan. additive manufacturing techniques that will help
print, on demand, parts anywhere in the world.

“Additive manufacturing allows us to fundamen-
tally explore new ways to build our products,”
says Melissa Orm, Vice President of Boeing
Additive Manufacturing. “We can create parts
that are practically or traditionally impossible.
“Additive manufacturing is also greener and
more sustainable than other methods because
the process uses less energy and resources and
creates fewer emissions, while the waste gen-
erated as a by-product of the process can be
© Amy Tolson_AvMC Public Affairs
more easily recycled and reused.”
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