U.S. Navy Accelerates Submarine Industrial Base with Advanced 3D Printing from AML3D

The defense sector, particularly within the United States, is undergoing a significant transformation driven by the integration of advanced manufacturing technologies. Among these, additive manufacturing, commonly known as 3D printing, stands out as a pivotal innovation. While its adoption spans across various branches of the military, its impact in the maritime domain, specifically within the U.S. Navy, has been exceptionally prominent. This trend is not only continuing but gaining substantial momentum, as evidenced by a recent strategic acquisition.

AML3D, an innovative Australian additive manufacturing company, has officially announced that the U.S. Department of Defense (DOD) will be acquiring one of their large-scale ARCEMY^® ‘X- Edition 6700’ systems. This sophisticated machine is slated for deployment at a critical U.S. Navy submarine base, where it will be instrumental in the rapid, on-demand production of industrial-grade parts. This move underscores the Navy’s commitment to leveraging state-of-the-art additive manufacturing capabilities to enhance its operational readiness and fortify its supply chain.

The U.S. Navy and the broader Department of Defense have consistently demonstrated a keen interest in the transformative potential of 3D printing. This latest acquisition is part of a series of strategic initiatives aimed at modernizing military manufacturing and logistics. For instance, just last year, the U.S. Navy established its own Additive Manufacturing Center of Excellence in Virginia, a hub dedicated to research, development, and implementation of AM solutions. Beyond infrastructure, 3D printing has already delivered tangible benefits, such as providing custom dental prosthetics to Navy personnel, significantly improving access to critical medical care. Furthermore, the USS Essex made history by becoming the first American ship equipped with a metal 3D printer onboard, demonstrating the practical application of AM for at-sea repairs and part replacement, thereby reducing reliance on traditional supply lines.

What makes this particular collaboration with AML3D noteworthy is its explicit focus on supporting the U.S. Navy’s submarine industrial base. While many earlier 3D printing projects within the Navy have concentrated on surface vessels, aiming to enable rapid repairs and production of parts while ships are deployed, the submarine sector presents unique challenges and opportunities. Submarines operate in highly demanding environments, requiring parts that meet stringent specifications for durability, performance, and safety. The supply chain for these specialized components can be complex and prone to delays, impacting maintenance schedules and overall fleet readiness.

For a period following the groundbreaking use of 3D printing to create a submarine hull in 2017, news on AM applications specifically for submarines was relatively scarce. However, this began to shift dramatically last year. The U.S. Navy publicly acknowledged that advanced 3D printing technologies would be crucial in addressing persistent supply chain vulnerabilities and bottlenecks that disproportionately affected submarine parts. The acquisition of the ARCEMY^® system from AML3D is a direct response to this strategic imperative, signaling a renewed and intensified commitment to bolstering the submarine fleet through advanced manufacturing.

The ARCEMY^® ‘X- Edition 6700’ system brings with it AML3D’s proprietary Wire Additive Manufacturing (WAM) technology. WAM is an advanced form of Directed Energy Deposition (DED) 3D printing, a process renowned for its capability to produce large-format metal components with high integrity. In WAM, an electric arc serves as the energy source, melting a welding wire feedstock to deposit material layer by layer, thereby building up a solid part. This method offers several distinct advantages, including high deposition rates, which translate to faster production times for large parts, and the ability to work with a wide range of commercially available metal alloys, making it highly versatile for demanding industrial applications.

The resurgence of DED technologies across various industrial sectors is largely attributable to their robust capabilities. Beyond manufacturing new parts, DED systems excel at repairing existing components, extending their lifespan and reducing waste. Their ability to create large structures, owing to relatively spacious build envelopes and efficient material deposition, makes them ideal for heavy industries like defense and maritime. For the U.S. Navy’s submarine industrial base, the ARCEMY^® system’s ability to produce on-demand, industrial-grade parts is a game-changer. It promises to dramatically accelerate the supply of critical components, minimize lead times, and enhance the overall resilience of the submarine fleet’s support infrastructure. This localized, rapid manufacturing capability is vital for maintaining an agile and responsive naval force.

Significantly, the ARCEMY^® system will be situated at the Oak Ridge National Laboratory (ORNL). As the largest science and energy laboratory within the U.S. Department of Energy system, ORNL is a hub of advanced research and technological innovation. Its extensive expertise in materials science, manufacturing processes, and large-scale engineering provides an ideal environment for the deployment and optimization of such a sophisticated additive manufacturing system. This strategic placement will not only facilitate the production of parts but also foster further research and development into new applications and materials for naval defense, pushing the boundaries of what advanced manufacturing can achieve for national security.

Ryan Millar, CEO of AML3D, expressed his enthusiasm for this groundbreaking collaboration, stating, “AML3D is incredibly excited to be supporting the US Navy’s submarine industrial base programs with the adoption of our advanced manufacturing technologies, specifically the ARCEMY^® ‘X-Edition 6700’ system, which represents our flagship large-scale, industrial-purpose solution. This sale is not merely a transaction; it represents a significant milestone and a tremendous opportunity for AML3D, as it forms the cornerstone of a long-term strategic partnership with the US Navy. Our goal is to actively assist them in scaling up critical submarine production capabilities through the deployment of our cutting-edge additive manufacturing technology. This pivotal opportunity with the US Navy and the broader Submarine Industrial Base perfectly aligns with ALM3D’s overarching strategy of prioritizing ARCEMY^® product sales, particularly within the dynamic and critical US maritime and defense sectors. We are confident that this partnership will serve as a strong foundation, and I eagerly anticipate providing further updates as we deepen our presence and cultivate new partnerships across the United States.” This statement highlights the strategic importance of the deal, not just for the immediate supply of parts but for establishing a robust, enduring relationship that will drive innovation in defense manufacturing. You can find out more details in the official press release HERE.

The integration of AML3D’s ARCEMY^® system into the U.S. Navy’s submarine operations marks a pivotal moment in the modernization of defense manufacturing. It signifies a clear shift towards decentralized, on-demand production, which is essential for maintaining a technologically superior and logistically resilient military force. This advanced approach promises to reduce reliance on vulnerable global supply chains, cut down lead times for critical components, and ultimately enhance the readiness and operational capabilities of the U.S. submarine fleet. As additive manufacturing continues to mature, its role in ensuring national security and driving technological advancement within the defense sector will only expand, paving the way for more efficient, agile, and robust military operations for decades to come.

What are your thoughts on the U.S. Navy’s strategic acquisition of the ARCEMY^® ‘X- Edition 6700’ system from AML3D and its implications for submarine manufacturing? We invite you to share your insights in a comment below or join the discussion on our LinkedIn, Facebook, and Twitter pages! Don’t miss out on the latest advancements in 3D printing – remember to sign up for our free weekly Newsletter here to get the most important news delivered straight to your inbox! You can also explore our comprehensive video library on our YouTube channel for more in-depth content.