It’s no secret that 3D printing is being used by the U.S. Defense Department for many interesting applications. Over the past few decades, we’ve seen several projects involving additive manufacturing. These include submarine manufacturing and dental 3D-printing on Navy ships. Even more exciting news is coming out of the Consortium for Additive manufacturing Research and Education at the Naval Postgraduate School. According to a recent press release, CAMRE worked with Marine Innovation Unit (MIU), Marine Aircraft Group 39 (MAG), and Marine Innovation Unit for the successful demonstration of 3D printing in flight aboard a U.S. Marine Corps MV-22 Osprey aircraft.
Perhaps you’ve heard of Naval Postgraduate School. The United States Navy runs the California-based, public graduate school. It aims to offer a graduate education that is defense-oriented to its students. It is also one of the pioneers in pushing the limits of military additive manufacturing. The NPS, in fact, was the first to investigate capabilities for additive fabrication for the Navy and Marine Corps. This included adopting ElemX, a Xerox product, to define different applications. So it should be no surprise that the latest innovation comes from them. Chris Curran explains the program manager of CAMRE. “We are in a unique position to rapidly support the joint force and accelerate the adoption of advanced manufacturing. This is just one of many events we are committing resources to where we share our research and deliver equipment and know-how to service members.”
The part was affixed to a U.S. Marine Corps MV-22 Osprey, like the one pictured (photo credit: Lance Cpl. Mackenzie Gibson)
Why are the Marines using 3D printing in flight?
Why 3D printing then? The same reasons that additive manufacturing is used in many different industries. The technologies’ flexibility and rapidity are expected to dramatically improve mission readiness, especially for rapid responses. The 3D printing process is particularly valuable for swarm robots and medical devices. As a matter of fact, the part that was 3D printed in-flight for the first time was a medical cast that had been created by a 3D scan of a Marine’s arm. The 3D scan was turned into a model using generative design software. The cast was then printed onto the Osprey as it engaged in various ground and flight modes including taxiing, takeoff, and in-flight manoeuvres.
Also noteworthy is the 3D-printer used for this demonstration. Spencer Koroloy is an engineer with the Naval Information Warfare Center Pacific, San Diego. He developed this system called Advanced Manufacturing Operational System. AMOS, according to a press release, is known for its speed, reliability, and ruggedness. All of these qualities are important when gear is required for military missions. We do not yet know what 3D technology is used. The focus being on medical products, any of the following could be used: extrusions, SLS or vat-photopolymerization.
3D printing is becoming more popular for medical devices. For example, HP has developed a 3D cast.
Lt.Col. Michael Radigan, MIU liaison to NPS, concludes. “We are just scratching the surface on the capabilities that will come from being able to 3D print in flight. Dozens of printers being installed in a modular fashion aboard aircraft brings the ability for mobile production at a scale we have not experienced before.” Press release – Click HERE to read more.
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