#3DExpress: The First Metal 3D Printed Valve Manifold Assembly Installed on an Aircraft Carrier

In this week’s #3DExpress, we start off with yet more news from the U.S. Navy. At Newport News Shipbuilding, a 3D printed metal valve manifold assembly has been installed in an aircraft carrier for the very first time. Next, see how Eplus3D has made large-scale copper additive manufacturing possible and how 3D scanning can help in boat maintenance. Wrap it up with Bosch’s new center for AM in the automotive sector in Europe and a major advancement in 3D printing breast prostheses from Lattice Medical. Happy reading and have a great weekend!

The First-Ever Installed 3D-Printed Valve Manifold on a U.S. Navy Aircraft Carrier

DM3D Technology, a leader in direct metal deposition (DMD) additive manufacturing, has announced the first-ever installation of an additively manufactured valve manifold assembly on a U.S. Navy aircraft carrier at Newport News Shipbuilding (NNS). NNS has been a longtime adopter of AM technologies, using 3D printed components in new nuclear subs and working to develop Copper-Nickel (CuNi) and Nickel-Copper (NiCu) alloy powders for 3D printing due to their suitability for maritime applications. This time, a valve manifold assembly, which allows distribution of a single source of fluid to multiple points on the ship, was made using metal 3D printing and has been installed in a pump room on Gerald R. Ford-class aircraft carrier Enterprise (CVN 80). “What started as a proof of concept quickly turned into a tangible result that is making a meaningful difference to improve efficiencies in shipbuilding,” explained Dave Bolcar, NNS Vice President of Engineering and Design. “The benefits of this innovation will extend well beyond Enterprise (CVN 80), as we incorporate our expertise in additive manufacturing into the fundamentals of shipbuilding.”

The valve manifold assembly in the pump room on Gerald R. Ford-class aircraft carrier Enterprise (CVN 80) (photo credits: DM3D)

Eplus 3D Unveils Meter-Scale, Red-Laser Copper AM

TCT Asia 2025 has closed its doors. But with the Asian AM market booming, it is not surprising to see some of the incredible advancements announced at the show. This includes one from Eplus3D. Building upon the success of its 64-laser EP-M2050 system, the company has now unveiled its capabilities for large-scale 3D printing of pure copper and copper alloys thanks to advanced red-laser technology. Copper can be difficult to 3D printing due to high reflectivity and low energy absorption, Eplus3D has overcome this with its own red-laser technology that is compatible with its existing large-format, multi-laser metal PBF machines including the EP-M2050, EP-M1550, and EP-M1250. To prove it, large parts were on display at TCT Asia, including a φ1030×175 mm CuCrZr impeller that has a 99.97% density while retaining copper’s thermal and electrical conductivity. 3D printed meter-scale copper parts would be well suited for industries like aerospace, automotive and electronics.