United States Army Working with UCF to Optimize 3D Printing Processes

Once again, the American military has shown its interest in using 3D printing. This time, United States Army researchers have collaborated with academic partners from the University of Central Florida (UCF) to work to optimize the additive manufacturing process. The researchers worked to successfully print and optimize a magnesium alloy, WE43, optimizing it to allow for higher density in micro-lattice structures. This is expected to potentially allow the army to deliver extreme lightweight components to future soldiers.

One of the many known advantages of 3D printing is its ability to produce parts that are lighter than those created using traditional methods. This is the main driver behind this particular research. American soldiers are expected to carry extremely heavy packs, for example, standard combat gear can weigh 43 pounds on its own, and that is not counting any specialized equipment soldiers may also carry. For this reason, research into how to literally lighten that load is of great concern. Or at least, that is how Dr. Brandon McWilliams, the lead research for 3D printing metals at the United States Army Combat Capabilities Development Command (DEVCOM) Army Research Laboratory, explains the reasoning behind the project: “Current systems are too heavy, which increases burden to the Soldier, reduces fuel efficiency and degrades mission effectiveness, It is my goal as an Army researcher to conduct research, which has the maximum chance of success of transition from basic and applied research stage to practical application in order to enable transformational overmatch.”

U.S. Soldiers are expected to carry heavy equipment with them on uncertain terrain. For this reason, increasingly the Army has looked into ways to lighten packs through technology like 3D printing (photo credits: .S. Army DEVCOM Army Research Laboratory)

The United States Army Research Project with UCF

Of course, this can be easier said than done, hence the research project with UCF which came from the United State. Army’s Open Campus initiative. The project sought to optimize the printing process for 3D printing a high-strength magnesium alloy and fabricating micro-lattice structures. A significant part of the research revolved around 3D printing with magnesium alloy. McWilliams noted “We used a magnesium alloy known as WE43, which has only been successfully 3D printed by a handful of researchers, in this work, we optimized the process to achieve higher density than previously reported and used that to produce and characterize lattice structures made up of WE43.”