by Melissa Donovan
Additive manufacturing (AM) in the defense and military sectors presents opportunity in terms of supply chain readiness and eventually on-site part production. The sky is the limit as users in this space turn to three-dimensional (3D) technologies from fused filament fabrication (FFF) to direct metal laser sintering (DMLS) to provide one-off parts as well as multiple pieces of the same item that can be integrated into advanced aerospace and naval equipment.
Above: Emergency exit frame for an air vehicle printed using titan material. Image from Gefertec.
Reliable Machines
Not surprisingly, the defense and military space utilizes many types of AM. This includes—but is not limited to—FFF, fused deposition modeling (FDM), wire arc AM (WAAM), laser powder bed fusion (L-PBF), DMLS, and lithography-based ceramic manufacturing (LCM).
Andy Middleton, SVP – EMEA, UltiMaker, says that for defense applications, the most effective AM technologies are those that combine ease of use with industrial-grade reliability. “Equipment needs to operate both in controlled environments and in the field, often by personnel who are not AM specialists. Systems that can process strong engineering materials, such as carbon fiber reinforced polymers, are particularly valuable, as they allow the production of durable end use parts, tools, and fixtures. The priority is to have a versatile, compact system that can respond quickly to maintenance and logistical needs, wherever they arise.” Of note, FFF—which Middleton believes is an ideal platform—offers “unmatched balance between performance and accessibility.”
For expeditionary and field applications, Eric Shnell, co-founder/CEO, Craitor, suggests FDM. “It’s extremely rugged; tolerant to shock, vibration, and orientation changes; and far less sensitive to environmental conditions. Just as importantly, FDM is easy to automate and carries the lowest training burden, which is essential when you’re deploying capability outside of a controlled facility.”
“We’re also seeing growing use of hybrid metal extrusion systems, which offer real flexibility for deployed metal part production. While these systems are more complex, they leverage common, stable feedstocks—like welding wire, making them increasingly practical for remote or military environment,” adds Shnell.
WAAM stands out as well suited for military applications. “It enables the production of large components, spare parts, and even repairs on damaged parts with ease. WAAM is highly robust and process secure, even in harsh environments, thanks to its use of an electric arc rather than a laser. WAAM uses welding wire—a far simpler and more practical material for field operations,” notes Sebastian Recke, senior key account manager, Gefertec GmbH.
“For very large and less intricate structures, especially in naval and maritime applications, WAAM is a potential solution,” agrees Dr. Behrang Poorganji, VP technology, Nikon Advanced Manufacturing Inc.
L-PBF printers are one of the more capable technologies for metallic components, according to Poorganji. This is because of its precision, repeatability, and ability to support complex, lightweight, high‑performance designs.
DMLS is another option. “DMLS offers substantial opportunities to strengthen and regenerate a robust supply chain. This technology is uniquely positioned to accelerate manufacturing capabilities within the military industrial base, supporting rapid response and production readiness,” shares Ryan Smith, project engineer – federal projects, EOS.
“DMLS and even selective laser sintering (SLS) enable the rapid production of highly complex geometries compared to traditional manufacturing methods. These AM processes also support the creation and testing of a range of design variations, allowing engineers to identify the optimal configuration for a given application,” says Jonathan Spragg, AM academy team lead NA, EOS.
Wire-laser metal 3D printing, a subset of directed energy deposition technology, is also used. According to Lukas Hoppe, research and development director, Meltio, the technology combines safety, reliability, and easy integration.
Thermal management components are another important application-group in this space. The ultra-precise digital light processing-based Lithoz LCM process uses technical ceramics known for their high thermal conductivity, high-temperature resistance, and low thermal expansion.
Dr. Johannes Homa, CEO, Lithoz, says LCM produces items like next-generation sensors and actuators for control systems. “Our technology combines the superior properties of high-performance piezoceramics with intricate structures. Another application scaled to low-volume serial production is by Safran Aircraft Engines, where ceramic casting cores are used to create cooling channels within single-crystal turbine blades for the next generation of aircraft engines. Complex ceramic components might not be the spectacular stars of the big stage, like large-scale propulsion units, but they are rather the ‘hidden champions’ that silently push military applications to a new level of efficiency and performance.”
“Engineers can fine tune internal geometries so they match the changing thermophysical properties of fluids or gases as they pass through a component. That freedom means higher surface area within the same volume, which improves heat transfer and overall efficiency. The resulting parts are smaller, lighter, and better performing than those made through conventional techniques, crucial advantages in aerospace and defense settings where every millimeter and gram matter,” explains Ben Batagol, commercial lead in North America, Conflux Technology.
Another technology is AM electronic (AME) printers, which Dr. Kenneth Church, CEO, nScrypt, says has the potential to make anything that is 3D printable smart.
“Electrically functional 3D structures will open the door to next-generation electronic packaging. For decades, planar packaging and stacking have been the norm, but AME is introducing shaped electronics that have the potential to impact electronics in much the same way AM transformed nozzles, shoes, hearing aid molds, dental aligners, and even buildings,” continues Church.
AM in the Real World
The increased adoption of AM in defense and military is influenced by advancements in the technology—hardware, software, and materials. Performance and reliability are non-negotiable and AM delivers.
Shnell points to strides in ease of use, consistency, and material capability as key to the AM technology growing in use in military and defense applications. “Systems that once required deep expertise are now far more automated and reliable, enabling high-quality output with minimal oversight. At the same time, improvements in process stability and advanced materials expand the range of applications AM can realistically support, making it a far more practical tool for real-world industrial and expeditionary environments.”
“AM also enables the production of higher complexity, higher functionality parts that would be impractical or impossible using traditional methods,” notes Poorganji.
With defense and aerospace applications demanding strength, precision, and reliability under extreme conditions, today’s large format AM systems are ideal because they are equipped with advanced thermal management and high-temperature mechanical performance, says Smith.
Suppressors are a prime example of progress in AM. “This application has seen substantial growth in recent years, largely due to the design flexibility, rapid prototyping, and performance optimization afforded by AM,” attests Spragg.
Hoppe says certain technologies help create more autonomy in the defense and military sectors. For example, Meltio’s wire-laser metal 3D solutions provide the opportunity for creating and repairing metal parts. The Meltio Robot Cell can print and repair metal parts in an enclosure solution including a robotic arm integrating with Meltio Engine.
AM materials have expanded and processes have matured, offers Church. “One advantage, a digital input or CAD file can be turned directly into a physical object. Another, the complexity that exists in a CAD file now exists in the printed part. Intricate patterns that dictate electronic performance are modeled and then printed.”
“AM has evolved from a prototyping tool to a practical means of maintaining and extending the life of complex assets. Defense organizations increasingly use it to decentralize production and shorten lead times for replacement parts and maintenance tools. Furthermore, digital part libraries and simulation-driven design are allowing engineers to validate, optimize, and replicate parts globally with complete accuracy,” continues Middleton.
Batagol agrees that AM is now reliable in production environments, moving far beyond its roots in rapid prototyping. “It’s now a proven production technology capable of delivering fully qualified hardware that meets demanding industrial standards. The machines themselves are faster and more consistent, which shortens design cycles and accelerates the ability to do testing and iterations. This maturity is one reason the technology is being adopted for defense platforms, where performance and reliability are non-negotiable.”
“Beyond speed, AM allows functional improvements such as integrated cooling channels or mixed-material designs, which enhance performance. The technology also delivers significant material and cost savings, making it both efficient and sustainable,” adds Recke.
Simplifying Logistics
AM is currently changing the manufacturing of military-type products and will continue to do so. It not only radically shortens supply chains, but also eliminates storage of parts.
The biggest transformation is the shift toward decentralized manufacturing, according to Recke. “Military units can produce critical components close to the field, dramatically reducing lead times and logistical complexity. This flexibility ensures that urgent demands can be met quickly, while simplifying supply chains and improving operational readiness.”
“AM plays a growing role in new weapon systems, sustainment activities, and on demand production. The ability to print parts at or near the point of need strengthens readiness, reduces logistical dependence, and offers resilience against supply chain disruptions. As a result, AM is becoming an essential capability within next‑generation defense manufacturing strategies,” says Poorganji.
It’s an on demand model that eliminates long supply chains. “Instead of waiting on traditional logistics, units can produce certified replacement parts on demand, simplifying support and sustainment. This aligns directly with the Department of Defense’s (DoD’s) growing emphasis on right-to-repair and organic maintenance capability. AM is quickly becoming the primary driver of that shift, giving military units the ability to keep critical systems operational without relying on long, fragile supply lines,” explains Shnell.
“In the near term, this means broader adoption of localized production units, including mobile or deployable setups, that can support maintenance and repair directly in operational contexts. The result is a more adaptive model of manufacturing that strengthens readiness and reduces logistical risks,” points out Middleton.
Mobile AM production cells allow parts to be made closer to where they are needed, reducing downtime and supply chain risk. “At the same time, AM enables onshoring of key components, giving nations greater control over the production of high-value defense assets. The benefits are tangible—AM allows for faster innovation cycles, where smaller design improvements are made more frequently. That agility is increasingly important for defense programs that need to adapt quickly to evolving operational requirements,” says Batagol.
“The military recognizes the speed at which new concepts can be produced. They also see that old parts can be replaced with identical ones without needing a warehouse full of spares. The concept of storing a CAD file for a part and printing it anywhere in the world is more than intriguing, it is life saving,” states Church.
This principle can be applied to electronic repair. “Repairing or replacing legacy boards from a digital file with an AME printer is impactful in terms of time, cost, and mission readiness. This is the future of military logistics,” adds Church.
AM is also “an effective solution for legacy part reproduction, particularly when original tooling or manufacturing methods are no longer available or cost effective,” notes Smith.
“The most common advantages of AM include weight reduction and accelerated deployment times. Through innovative design strategies, AM enables the production of lighter components that enhance portability and ease of deployment. Additionally, the ability to manufacture parts rapidly allows critical components to be produced and delivered to operational areas much faster than with conventional manufacturing methods,” adds Spragg.
AM provides “freedom of design to iterate and innovate applications within days instead of months,” argues Homa. However, “for military decision makers, the superior agility of AM production units for on demand, on-site supply of critical spare parts in the field is the real pull for AM into defense.”
And this is specifically where ceramic AM steps in “to redefine how refined and fast ceramic sensors, radomes, ceramic cones, or thermal management applications for the cooling of advanced propulsion systems are created. Even more intricate features needed and only achievable via LCM technology are complex internal channels, functional porosity gradients, and fully optimized cooling structures,” adds Homa.
Challenges Met
Despite the advancements and growth in this sector, challenges continue to pop up and must be addressed.
Shnell suggests that the biggest challenges now center on standardization, secure access to parts, and ensuring consistent, repeatable output. “The DoD needs a way to reliably source the right technical data, maintain chain of custody for controlled parts and intellectual property, and trust that printed components will perform the same way every time—regardless of who is operating the printer or where it’s deployed.”
“Manufacturers address this by building secure digital part libraries, embedding traceability and authentication into the workflow, and developing highly automated systems that reduce operator variability. At the same time, there’s a major push toward scalable, repeatable architectures so the military can deploy AM capability across units of all sizes without sacrificing quality or control,” adds Shnell.
Poorganji agrees that process stability and repeatability is an issue, in addition to the qualification of machines, materials, and processes, as well as industry-wide standardization. Scalability, supply chain reliability, and secure vision control are also critical.
“Key challenges include ensuring part performance, managing material quality, and maintaining data security. Every component printed for defense use must meet strict functional and safety requirements,” shares Middleton.
Part of meeting requirements means creating some type of industry-wide standardization, which Batagol says is ongoing. “Defense has traditionally used proprietary testing regimes, but organizations such as ASTM are making progress toward harmonized frameworks for AM parts. Another consideration is building a trusted production ecosystem that meets the defense sector’s evolving needs. AM suppliers, OEMs, and end users are now working more closely to establish transparent processes, from design to inspection, that can be validated under real-world conditions. This collaboration is key to increasing confidence and adoption in mission-critical programs.”
“Bottom line, speaking of reliability, scalability, flexibility, qualification, and supply chain resilience, it all comes down to one prime factor—only by delivering absolute excellence in quality, the AM industry will not only enjoy a short boom period in the military sector but successfully establish sustainable long-term partnerships built on mutual trust,” explains Homa.
Logistics is another challenge. “While AM reduces dependency on traditional supply chains, ensuring the availability of raw materials and maintaining equipment in remote locations requires careful planning,” notes Recke.
While AM from the top level is a mature technology—with consolidation between vendors common practice the last few years—Church sees AM leveling off and moving toward real applications and real impact. AME, however, is still a new kid on the block and requires more understanding.
“One challenge we face in AME is the lack of maturity and understanding compared to traditional, well-established processes. Material sets are modified and electronic developers are uncomfortable with that. They frankly cannot think in 3D. Their mindset is still 2.5D—stacking. Early adopters can see the potential, but traditional manufacturers struggle. AME can handle smaller parts, more material options, and do what it is naturally made to do—fully use that third dimension. The pressure from electronic demand will drive this. Creativity from early adopters will move the needle,” continues Church.
The military and defense sector also faces the challenge of the shutdown or reduction of traditional casting and manufacturing facilities. The good news, Smith says, “is that AM can serve as both a replacement and an enhancement for casting processes, producing near-net-shape components that require minimal post processing. This not only streamlines the production workflow but also reduces material waste and scrap, improving overall efficiency and sustainability.”
Highly Agile
AM is expertly poised to play a large role in manufacturing parts for the military and defense sectors. The technology is growing and changing, influencing how quickly and where items like sensors, thrusters, and casting cores are built.
Printing at point of need is the new reality. Mobile 3D production not only reduces downtime but eliminates risk. When it comes to high-value assets moving through the supply chain, a significantly shorter path of delivery is preferred.
“Military forces think and act in a highly agile way. Shorter lines of reinforcements and lean production are key to enhance dynamics. AM technologies meet this need by enabling faster, more flexible, and more resilient supply chains across air, land, and naval systems,” says Homa.
Feb2026, Industrial Print Magazine
