Maximizing military efficiency with additive manufacturing

Netherlands-based 3D printer manufacturer UltiMaker recently published a white paper on 3D printing (3DP) solutions for military and defense applications. Defense and Munitions summarizes the key findings.

Challenges of manufacturing, maintenance, and logistics for a modern military

Today’s global militaries have a heavy reliance on support staff and supply chains. The tooth-to-tail ratio (TTR) measures the ratio of combat fighters to support personnel. In WWI the U.S. Army had a TTR of 1:2. Today, that ratio has grown to 1:10 – meaning most personnel play a support role.

Why the change?

Modern weapon systems and technologies are more capable than in the past so fewer combatants are required to have the same impact. However, the complexity coming with highly capable, sophisticated technologies means they often require extensive preventive maintenance from trained technicians to keep them operational and ready, even in peacetime. Beyond defense support personnel, private industry provides more support in the development, manufacturing, upgrades, and maintenance of weapons and technologies. With such a major focus on R&D, manufacturing, maintenance, and logistics, it’s not surprising 3D printers have become critical tools for defense contractors and within defense units themselves.

Manufacturing jigs and fixtures for defense supply chain

The U.S. defense industrial base includes private facilities producing defense items, from major contractors to small businesses and innovators. It comprises factories, shipyards, and a skilled workforce, ensuring readiness and adaptability to evolving defense needs, essential for maintaining national security and technological advancement.

While goods can vary widely from clothing to heavy armored vehicles and aircraft, 3D printers offer the flexibility to rapidly improve the manufacturing processes over time. Changes can come in more ergonomic or efficient tools, inspection gages, organizers, and new jigs and fixtures. 3D printers are becoming critical for the design, production, and replacement of tools, essentially providing tools on demand.

What are 3D-printed manufacturing tools?

Manufacturing tools, in the context of 3DP, aren’t machined molds churning out thousands of injection molded parts. Instead, they’re very specialized devices making technicians, engineers, and robots on the line more effective.

Manufacturing engineers understand customized tools, jigs, and fixtures increase speed and efficiency by making the job of assembly line workers easier and more repeatable.

They also reduce the risk of defective equipment being delivered to frontlines by reducing the chance of mistakes or inconsistencies during production.

Why 3D print manufacturing tools?

3D printers are valuable mini manufacturing plants that can work next to the line and provide access to new or replacement tools.

Easy to access, easy to use

3D printers significantly reduce the physical effort required to create objects. Modern desktop 3D printers are powerful and user-friendly, featuring a compact design allowing them to be conveniently placed where needed. This accessibility makes them ideal for engineers.

Unlike CNC machines, 3D printers are extremely easy to use, enabling almost anyone to produce a part with minimal training. Additionally, they don’t need specialized work areas with industrial ventilation, dust collection, or other facilities.

• Live process optimization Using 3D printers for on-demand manufacturing also allows for rapid iteration and optimization of tools and processes. If you receive feedback from line operators that a certain jig is difficult to use and could benefit from an additional handle for better ergonomics, you can easily address this. Simply open the CAD file, add the handle, and print the revised version in a single day. This process is also applicable to specification changes or new vehicle models, enabling the quick setup of new production lines and adapting to any modifications.
• On-demand replacements Maintaining a digital inventory enables an engineer on the plant floor to access an unlimited library of parts without the necessity and costs of a large warehouse. A 3D printer can produce validated parts on demand. A batch of 20 nozzles for applying window sealant can be printed in a single run. All that’s required is a 3D printer, a few spools of filament, and a computer.

Maintenance, repair, and overhaul (MRO) with 3D printers

In the last decade, the U.S. Army, Air Force, and Marines have adopted a leaner approach to equipment maintenance called two-level maintenance. This enables greater efficiency using technologies such as advanced sensors, diagnostics, and modular designs – allowing for more effective reactive and preventative maintenance to occur in the field rather than at the depot or factory level.

The U.S. Navy’s traditional rule of thirds with their vessels (1/3 deployed, 1/3 in drydock, 1/3 in replenishment) means most vessels aren’t actively used. Similarly to the other armed forces, there’s a push to improve preventative maintenance in the field to reduce downtime by leveraging modern technologies.

• Why 3D printers in defense maintenance? While modular components are already enabling better field maintenance and reducing massive in-theater depots and long supply lines with transport vehicles, there’s still room for improvement. Defense logistics and maintenance officers are starting to realize the potential of 3D printers in field and sustainment maintenance.
• Replacement part production Traditional defense maintenance supply chains require in-theater storage of replacement parts, meaning large space requirements and replenishment via transport. By leveraging 3DP, planners can create catalogs of 3D printable parts that can be stored digitally. Then when a modular component needs to be replaced, the unit’s technicians can download the file and print the necessary components. Thanks to the evolution of 3DP technology, high performance materials such as carbon fiber composites and metals can be leveraged.
• On-demand tool sourcing Much like replacement parts, tools for maintenance require extensive storage. In some cases, the right tool for the job may break, be in short supply, or not exist at all. This is where the versatility of 3DP comes in. Digital catalogs of tools can be made available to print on-demand, so if the tool you need is constantly being used by another tech, just print another one. If a mechanic needs a specific fixture or tool they don’t have, they can step into CAD with the specs and design and print that tool in 24 hours.
• Portability, accessibility Part output is one factor, but if the tool or process is too cumbersome, it won’t be useful in the field. 3D printers come in a wide range of shapes and sizes. Professional desktop models can pack a major punch while being compact and portable all-in-one manufacturing stations. They can be deployed in forward areas with quick setup and are relatively easy to use. There are even examples of 3D printers being used within all-terrain heavy-trucks – serving as automated manufacturing workstations within mobile workshops.

What is the traditional defense resupply chain?

• Traditional manufacturing Historically, militaries got their supplies in the field, carried them with them, or shipped them in from the rear. Today military supply chains focus on carrying and shipping supplies using large convoys, cargo aircraft, and tactical pack robots.
• Additive manufacturing 3DP offers unprecedented flexibility and efficiency. 3D printers can be stationed anywhere in the world and produce parts on demand, allowing for localized manufacturing, reducing shipping times and inventory costs while meeting specific, immediate needs.

How do 3D printers fill gaps in the defense supply chain?

Unlike the traditional supply chain relying on heavy transport vehicles moving provisions from manufacturing or storage facilities to bases or near the front lines, 3D printers can be positioned to manufacture goods on location. They can fill supply chain gaps due to unexpected rise in demand, bad weather, or even adversarial denial. While the major equipment required on the battlefield is unlikely to be fully 3D printed, there are examples where 3DP makes a lot of sense.

Base/shipboard infrastructure

Forward operating bases are hubs for deployments and are often built from the ground up to be self-sufficient. Similarly, naval ships can be deployed for months in locations where resupply can be challenging. Having 3D printers on-location enables immediate manufacturing of a wide range of goods such as hooks, handles, valves, switches, gears, and clips. Printing these parts can cut wait times from weeks to days and reduce resupply missions.

Medical, health care

Health care is critical to successful military deployment. 3D printers are already a normal sight in the dental community, and medical applications are becoming more common. Aside from custom surgical implants based on CT scan data from the patient’s own anatomy, more basic applications including anatomical splints and braces and replacement ambulatory equipment can be 3D printed on-demand without the need for resupply.

Mission-specific customizations

Standard operating procedures don’t always work as planned. Battlefield improvisation can play a critical role in certain mission situations. 3D printers can deliver customized solutions that can help units achieve their mission. These one-off tools can be prototyped but also used in the field and modified based on feedback for maximum impact. Designs can then be shared with defense contractors for mass production where it makes sense.

UltiMaker
https://ultimaker.com