U.S. Military Increases Fleet Readiness With 3D Printing

The United States Navy is continuing its exploration into using additive manufacturing at sea and ashore. More specifically, at The Rim of the Pacific Exercise (RIMPAC) 2024), NPS students showed how 3D printing could be used to increase fleet readiness. Notably, they were able to show how additive manufacturing can be used for ship repair.

RIMPAC is the world’s largest international maritime exercise, held biannually on even-numbered years. This year, it took place between June 26th and August 2nd in and around the Hawaiian Islands. It is the 29th time the exercise has held place and was centered on the theme of being integrated and prepared with 29 nations, 40 surface ships, 3 submarines, 14 national land forces, over 150 aircraft and more than 25,000 personnel participating. This is what made it the perfect place to test the applications of technologies like additive manufacturing, especially when it comes to repairing parts on ships.

Retired Marine Corps Col. Patrick Tucker, Marine Corps Lt. Col. Michael Radigan, Navy Lt. Cmdr. Zachary Vrtis, Lt. Ashley Adams and Lt. Andrew Staley showcasing parts made with the XSPEE3D expeditionary cold spray printer (photo credits: NPS)

“Ship and submarine repair is one of our crucial focus areas,” explained Navy Lt. Cmdr. Zachary Vrtis, an engineering duty officer currently pursuing a doctorate in mechanical engineering with a dissertation focused on metal additive manufacturing. “We are working to implement advanced metal manufacturing to better supplement traditional fabrication methods, repair fleet assets quicker, and assist in revitalizing the submarine industrial base to meet production goals.”

Using 3D Printing to Improve Fleet Readiness

During the exercise, Ten NPS students from the U.S. Navy, U.S. Marine Corps, and U.S. Army, along with representatives from the school’s Consortium for Advanced Manufacturing and Research (CAMRE) and FLEETWERX, spent time aboard ships and in installations to use metal additive manufacturing to produce repair parts. Furthermore, the CAMRE team was present aboard the San Antonio-class amphibious transport dock ship USS Somerset (LPD 25) and a Joint Advanced Manufacturing Cell was in place ashore at Marine Corps Base Hawaii. It was in these areas where the ability of 3D printing to improve fleet readiness was tested.

More specifically, it seems that the XSPEE3D cold spray 3D printer and a hybrid wire directed energy deposition machine from Snowbird Technologies were used. The XSPEE3D 3D printer from SPEE3D has been designed specifically for deployment event in remote locations and harsh conditions. It can manufacture parts of around 0.9m x 0.7m or approximately in diameter and 40kg using aluminum, aluminum bronze, stainless steel or copper. The DED solution from Snowbird Technologies is similar in that it is a 10-foot, containerized and deployable metal additive manufacturing platform powered by a Meltio print system, FANUC controls, and Creaform 3D scanning capabilities. Thus showing that for the U.S. Navy, 3D printing is most useful for fleet readiness when it comes as a mobile platform that can be deployed where needed. Which makes sense considering the nature of most conflicts.

Installing 3D-printed stainless steel reverse osmosis pump sprocket bushing aboard USS Somerset (photo credits: NPS)

And it seems that the exercise was a great success. Notably, one significant accomplishment was the use of additive manufacturing to repair a reverse osmosis pump, preventing the U.S.S Somerset from needing to end its participation in RIMPAC 2024 early. Furthermore, it was proven that having access to these AM solutions ensured rapid repairing, reducing reliance on distant logistics. This means that by using 3D printing, fleet readiness will increase as they will no longer need to rely on legacy components with unacceptably long acquisition lead times.

“This innovative technology [3D printing] is becoming an increasingly game-changing capability that is improving operational readiness and afloat self-sufficiency,” concluded Navy Capt. Jeremy Gray, who serves as surface warfare chair at NPS. “The partnership between Commander Naval Surface Forces and NPS is accelerating fleet experimentation and Sailor experience with advanced manufacturing techniques and processes.” You can find out more from the U.S. Navy’s press release HERE.

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*Cover Image: The U.S.S Somerset arrives at Pearl Harbor in Hawaii for RIMPAC 2024 (photo credits: NPS)