3D printing technology enhancing logistics for Army

A Soldier holds a cap used to protect the fire extinguishing system housed in the wheel wells of Mine-Resistant Ambush Protected vehicles. Without the cap, MRAPs are deemed non-mission-capable. Soldiers in Korea saved 1,472 operational days for their MRAPs by 3-D printing the caps for about $2.50 each.
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This photo shows a 3D printer producing six-inch cap, used to protect the fire extinguishing system housed the wheel wells of Mine-Resistant Ambush Protected vehicles. Soldiers in Korea identified a fire-suppression cap degradation issue and turned to 3D printing technology for help. The team requested engineering support from the Armament Research, Development and Engineering Center at Picatinny Arsenal, N.J.
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FORT MEADE, Md. — As 3D printing increases both in the field and at depots, the Army’s Center of Excellence for Additive and Advanced Manufacturing is slated to reach initial operating capability this year at Rock Island Arsenal, Illinois.

Lt. Gen. Aundre Piggee, the Army’s deputy chief of staff, G-4, outlined the Army’s current 3D printing capabilities at the 2019 Military Additive Manufacturing Summit and Technology Showcase Feb. 6, in Tampa, Florida. 

At the summit, defense, academia, and industry officials were privy to the latest additive manufacturing technologies, event officials said. The Army will leverage these improved 3D printing capabilities to bolster equipment readiness and reduce logistics burdens, Piggee said.

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3D printing applied to MRO of F/A-18 Hornet by U.S. Marines

A pilot looks out of the canopy of his F/A-18F Super Hornet aircraft. U.S. Navy photo by Cmdr. Ian C. Anderson

At the U.S. Marine Corps Air Station (MCAS) Iwakuni, southern Japan, 3D printing is now in use to keep F/A-18 Hornet multirole fighters airborne.

MCAS Iwakuni engineers have devised two products that reduce the time it takes to repair the fighter jets, saving costs for the U.S. Department of Defense. The products help with the maintenance, repair and overhaul (MRO) of the fighter jets, covering all tasks carried out to ensure the airworthiness of an flight vehicle.

The 3D printed products include an engine ship kit, designed by the Marine Aviation Logistics Squadron 12 (MALS 12), and a plastic ring kit that helps the maintenance of the bearings on the F/A-18’s Gatling gun.

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Fathom and U.S. Marines create modular logistics vehicle with additive manufacturing

FATHOM, a Californian design studio, has used additive manufacturing to create a Modular Logistics Vehicle (MLV) for the United States Marine Corps (USMC).

An MLV complete with 88 3D printed parts. .Image via Launch Forth.

Frustrated by the unresponsiveness of traditional supply chains, Marines from the 29 Palms base generated the concept of converting standard utility vehicles into customizable transport suited for a diverse range of missions.

This project was facilitated by the Launch Forth platform, as well as Deloitte, and Siemens.

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NAVSEA approves first metal 3D printed shipboard component for US Navy

The U.S. Navy’s Naval Sea Systems Command (NAVSEA) has approved the first 3D printed part, a prototype drain strainer orifice (DSO) assembly, for shipboard installation.

The 3D printed prototype drain strainer orifice (DSO) assembly component. Photo via NAVSEA.

“This install marks a significant advancement in the Navy’s ability to make parts on demand and combine NAVSEA’s strategic goal of on-time delivery of ships and submarines while maintaining a culture of affordability,” said Rear Admiral Lorin Selby, NAVSEA Chief Engineer and Deputy Commander for Ship Design, Integration, and Naval Engineering.

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U.S. Marines 3D print F-35 part to save US$ 70,000

A team of U.S. Marines 3D printed a part for the F-35 stealth fighter saving $70,000 in costs for a whole new landing gear door.

The landing gear of F-35A Lightning II. Photo via the Eglin Air Force Base

The component is a small part mounted on the door pressing it into the latch. It was designed and 3D printed by Marines from Combat Logistics Battalion 31 (CLB-31) in Carderock, Maryland.

Sam Pratt, a mechanical engineer at the Carderock’s Additive Manufacturing Project Office, provided further technical assistance to the team.

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US Navy will rely on 1,000 3D printed parts by the end of 2018

The U.S. Naval Air System Command (NAVAIR) is ramping up production of 3D printed parts.

System Command estimates that it will have approximately 1,000 3D printed parts approved for use across the fleet before the end of 2018. Currently only 135 3D printed parts are authorised for use.

3D printing helmets to flight-critical parts

3D printed parts will be used in a range of Naval applications, from modifications to helmets to critical parts for aircraft: NAVAIR categorizes parts depending on their air-worthiness. Parts not requiring airworthiness can be fabricated more quickly.

Fabricating a MV-22B nacelle link inside a directed energy deposition 3D printer. Photo via NAVAIR.

In 2016 NAVAIR proved that 3D printing could be used to produce safety-critical parts with the successful flight of an MV-22B Osprey, fitted with a 3D printed titanium engine nacelle link and attachment. Last spring, a 3D printed flip-top valve was added to the T-45 Goshawk breathing mask, allowing pilots in training to breathe cabin air up to a certain altitude. 300 valves were printed within a month without which training would have been impossible.

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Boeing partners Oerlikon to speed up adoption of 3D printing

Boeing is co-operating with Swiss engineering group Oerlikon to jointly develop additive manufacturing processes in a bid to accelerate the technology’s wider employment.

Oerlikon says it signed a five-year collaboration agreement with the US airframer to create “standard materials and processes” for the production of “structural” titanium components through 3D printing.

“The research will initially focus on industrialising titanium powder bed fusion additive manufacturing and ensuring parts made with this process meet the flight requirements of the US Federal Aviation Administration and Department of Defense,” says Oerlikon.

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Marines test system to 3D-print spare parts in the field

A U.S. Marine Corps infantry battalion has become the first unit in the Corps to possess a 3D printer, using it to printing various pieces of equipment.

The U.S. Marines said the unit is the 2nd Battalion, 8th Marine Regiment at Camp Lejuene, N.C., which has been testing how the system can be employed in various theoretical situations in the field.

“We’re at the tip of the iceberg as to what capabilities this can bring,” Capt. Justin Carrasco, the logistics officer for the battalion, said in a press release. “So right now, we’re identifying different 3D-printed parts that can support the warfighter in the expeditionary environment.”

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Lockheed Martin looks to catch up in 3D Printing

With all of its accomplishments – including world’s largest defense contractor, and a presence in all 50 states and 70 countries – you might think Lockheed Martin (Bethesda, MD) would already have mastered additive manufacturing.

Lockheed Martin’s Robert Ghobrial coined the phrase, “The 5Ps of Additive Manufacturing™,” a manufacturing model that describes how AM can help aerospace, defense and other businesses. But like manufacturers around the world, some of Lockheed’s experts are struggling to answer questions posed by 3D printing, according to Robert Ghobrial, additive manufacturing lead for the company’s training and simulation location in Orlando, FL.

“Should we invest in the technology today or wait until it’s faster and cheaper?” Ghobrial has asked himself. “Should we have a centralized or localized printing model?”

Ghobrial spoke at SME’s “Additive Manufacturing Applications: Innovations for Growth” seminar in October, at advanced energy technology accelerator NextEnergy, in Detroit.

He traced his work with 3D printing back to 2012, when his team received some MakerBot printers that largely went unused. Even as recently as 2014, he was mostly making trinkets from the Thingiverse digital design company, Ghobrial said.

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How disruptive is 3D printing really?

The concept of disruption and its applicability has been widely discussed over the past year. Digital technologies such as 3D print and additive manufacturing have been labelled game changers and potential disruptors, also for the maritime industry. The technologies are not widely applied in maritime yet, but more and more companies are looking into the potential changes and development opportunities of the technologies, both in terms of manufacturing, but indeed also in terms of new business models.

On 26 October Swedish Maritime Technology Forum (SMTF) and Green Ship of the Future (GSF) have invited MAN Diesel & Turbo, GKN Aerospace, Hoedtke, Alfa Laval and OSK Shiptech to discuss the potential for added value if applying 3D print and/or AM in maritime.

Over the past 6 months, GSF and 20+ maritime companies have deep-dived into the opportunity space for 3D printing in maritime, guided and inspired by 3D print and disruption experts such as DareDisrupt, but also main industry players such as General Electric, Siemens, Airbus AP works etc.

This event marks the conclusion of the project, but also the start of a new process where focus will be on practical appliance of 3D print in maritime companies and further investigation of new business.

You can learn more about the event here.