Customized Defense: How Additive Manufacturing is Reinventing the Production Chain
Additive manufacturing in the defense sector has surpassed the experimental phase. It is no longer just about emergency repairs in the field: 3D printing has become a primary production process for new components, with structured programs involving dozens of companies and million-dollar investments.
From emergency to strategy: additive manufacturing enters the DNA of defense
Additive production is no longer confined to emergency solutions but becomes an integral part of production planning and military supply strategies.
The change is evident in the numbers. The Defense Logistics Agency has involved 24 companies in the fourth round of its qualification program, for a total value of 9.8 million dollars. The goal: to build a network of qualified suppliers to accelerate the introduction of 3D-printed parts in aircraft, naval vessels, and military vehicles.
Applications range from armored vehicle components to naval artillery shells with a 5-inch diameter, produced via direct energy deposition instead of forging. Collins Aerospace has installed two machines with 12 lasers each, concentrating work in a single room that previously required an entire supply chain.
- 24 companies involved in the DLA program for 9.8 million dollars
- Production of critical components such as naval shells and parts for armored vehicles
- Reduction in delivery times exceeding 80% in some cases
The growth of the aerospace and defense sector of 3D Systems exceeded 15% in 2025, with forecasts of acceleration beyond 20% in 2026. The National Defense Authorization Act provided further impetus, introducing restrictions on the supply of AM machines from selected countries.
Special materials in circular optics: the case of tungsten alloys
The recycling and reprocessing into powder for 3D printing of advanced materials such as tungsten alloys is opening new frontiers for sustainability in defensive processes.
6K Additive has recorded an increase in demand for refractory materials for armored vehicle components. The company's response passes through programs of
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Q&A
- How has the role of additive manufacturing changed in the defense sector?
- It has moved from a tool for emergency field repairs to a primary and strategic production process. Today it is an integral part of production planning and military supply strategies, with structured programs involving dozens of companies and million-dollar investments.
- What are the key data points of the Defense Logistics Agency (DLA) qualification program?
- The DLA involved 24 companies in the fourth round of the program, for a total value of 9.8 million dollars. The goal is to build a network of qualified suppliers to introduce 3D printed parts into aircraft, naval vessels, and military vehicles.
- What military components are produced with additive manufacturing and what technologies are used?
- The applications include components for armored vehicles and naval artillery shells with a diameter of 5 inches. The latter are produced via direct energy deposition, an alternative to traditional forging.
- What operational advantages has the adoption of 3D printing brought to defense?
- In some cases, a reduction in delivery times exceeding 80% has been recorded. Collins Aerospace has also concentrated work that previously required an entire supply chain into a single room, drastically simplifying productive logistics.
- How is the additive manufacturing market developing in the defense and aerospace sector?
- The defense and aerospace sector of 3D Systems has exceeded 15% growth in 2025, with forecasts of acceleration beyond 20% in 2026. The National Defense Authorization Act has also introduced restrictions on the procurement of AM machines from selected countries, influencing the market.
- What is the contribution of additive manufacturing to sustainability in defense processes?
- Recycling and reprocessing into powder for 3D printing of advanced materials such as tungsten alloys promotes a circular approach in defense processes. The company 6K Additive is responding to the growing demand for such refractory materials for armored vehicle components.
