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3D printing in the military


The Military Turns to 3D Printing

The military is always looking for ways to stay ahead of the curve, and incorporating 3D printing into the defense sector is one way in which they are doing just that. 3D printing is being used by military units from different countries all over the world. They are creating everything from replacement parts for critical vehicles, ships, and aircraft as well as new designs for safety equipment being worn by service members to prototypes for new defense weapons, medical supplies, and even runways and bunkers.

3D printing technology is revolutionizing the way militaries around the world procure and maintain their equipment. In the future, 3D printing will become even more prevalent in the military, with the technology being used to print everything from weapons and ammunition to food and medical supplies.

One of the biggest advantages of 3D printing is that it allows for on-demand manufacturing, which means that militaries can print the items they need when they need them. This could be particularly useful in combat situations when time is of the essence and traditional supply chains are disrupted.

The use of 3D printing in the military enables them to be more self-sufficient. With 3D printers, militaries can print replacement parts and components for their equipment, rather than having to rely on outside suppliers. This could be a critical capability in wartime, when enemy forces may try to cut off supply lines.

3D Printing Spare Parts for the Military

Photo courtesy of Ultimaker

One area where the military is using 3D printing is to create replacement parts for land vehicles, ships, and aircraft. In the past, if something needed a new part, it would have to be ordered from a manufacturer and then shipped to the military base or flown in for a vessel deployed at sea.

This could take weeks or even months, especially with the current supply chain issues plaguing the entire world and keeping important parts stuck in ports due to chip shortages and pandemic-created backlogs.

With 3D printing, the military can create the parts they need on-site whether that is on base, at the front lines, or at sea. In a matter of hours or days, they can be up and running again which can be critical in a warzone or where lives are in danger.

Thanks to 3D printing technology, vehicles, and other legacy machinery can be kept out of retirement much longer when a spare part is able to be 3D printed to put it back into service.

Instead of spending thousands of dollars to have a single custom part made, they are able to design and 3D print it in tough materials and even metal to save millions of dollars a year.

Creating Tools and Jigs

Photo Courtesy of the Ultimaker

The various branches of the military have all discovered the benefit of 3D printing when it comes to creating tools and jigs to repair current equipment or install new parts.

Whether that is a 3D printed multitool they can clip to their belts or jigs that can help guide them to attach helicopter blades more safely, the possibilities are endless for the Department of Defense when it comes to 3D printed tools.

The military has always been on the cutting edge of technology, and 3D printing is no exception. The ability to quickly and easily create complex tools on the fly in a matter of hours is a huge asset in any field, but especially on the battlefield where time is often of the essence and sometimes lives are at stake.

Using 3D Printing to Improve Strength and Durability of Equipment

Photo courtesy of Ultimaker

3D printing technology is being used by the military to create prototypes and design new equipment. This technology benefits the military because it allows for the faster creation of prototypes and quicker turnaround times for design changes. Additionally, 3D printing can be used to create customized parts and pieces that fit the specific needs of the equipment and improves workflow.

Photo courtesy of Ultimaker

Sometimes it is as simple as designing housings for existing equipment to help protect it from damage in combat or during heavy use. For example, in the image above, a strong 3D-printed enclosure was designed to protect an antenna from being snapped off near the base during heavy use and driving through thick brush.

Photo courtesy of Ultimaker

There are countless ways in which the Military is using 3D printing to improve the workflow of their service members as well as protect the gear they already have while also ensuring a longer life for those pieces of equipment as they are being used on a daily basis.

3D Printed Medical Devices and Supplies for the Military

Photo courtesy of Ultimaker

Another area where the military is using 3D printing is to create medical supplies. This is especially important in combat situations, where time is of the essence. 3D-printed medical supplies can be produced quickly and easily in the field, which means soldiers can be treated faster and have a higher chance of survival in combat situations.

From custom-made Epi-Pen carrying cases and stethoscopes to I.V. line control, tracheal tubes, splints, casts, covid swabs, face shields, earplugs and so much more – the department of defense units around the globe are finding hundreds of ways to create medical devices with 3D printing technology.

3D Printed Military Bunkers, Bridges, and Runways

Photo Courtesy of the US Army

The military has partnered with companies like ICON to start building 3D-printed barracks to house service members for training missions. They have also been using 3D printing to create bunkers, vehicle hide structures, bridges and buildings in various locations around the world to serve to support and house military personnel and machinery at bases as well as in the field.

These large structures are being created using giant robotic 3D printers that extrude concrete. Once the military use has ended, the buildings, bridges and structures can then be left behind after a natural disaster or wartime mission for local communities to use once the mission is complete.

Photo courtesy of the US Airforce

3D printed runway panels are also being created for use in areas where the runways are unstable and too dangerous for military personnel to land safely or where there is no runway at all and military aircraft need to land in order to complete their missions or bring in supplies to ground troops.

Using 3D Printing to Make Propellers, Vehicle Hulls and More

Photo Courtesy of Naval Group

French company Naval Group has 3D printed a propeller which is composed of five 200 kg blades. The propeller was eventually fitted to the Andromeda, a mine-hunting ship. By using 3D printing technology they have drastically reduced the construction time and minimized the number of materials used to create this component and saved thousands of dollars in the process. 

Photo courtesy of the US Army

The Applied Science & Technology Research Organization, (also known as ASTRO America), has been been working on the Jointless Hull Project with the US Army to develop and deliver a hull for combat vehicles. Their hope is that this project will help to reduce manufacturing time and lower production costs. This will also reduce the weight of the vehicle and increase its performance and survivability for the service members who are manning them.

There are countless ways in which the military is currently working to make lighter weight and safer machinery, equipment and vehicles for use in combat as well as daily operations. 3D printing is also allowing for designs that can be repaired quickly and easily, on the spot without need to rely on outside manufacturers and supply chain issues.

Prototyping Safety Equipment with 3D Printing

Photo courtesy of the US Army

For the military, 3D printing is also opening up a whole new world of possibilities in areas where they are constantly looking to improve functionality, safety, and comfort for their service members.

For example, General Lattice and the U.S. Army have paired up to improve the impact absorption of the Army’s combat helmet through 3D printing by incorporating advanced lattice geometries. The hope is to improve soldier protection in the field and a higher chance of survival after suffering a head impact. The 3D printed materials will be tested in real-world situations to help improve the design and ultimately begin implementing its use in the field.

Whether they are reworking designs for face shields, masks, and other pieces of safety gear, now more than ever, the ability to 3D print a prototype and make adjustments in a matter of minutes is crucial.

The Future of 3D Printing in the Military

Photo courtesy of Ultimaker

In the future, 3D printing technology will become even more sophisticated and widespread, and it will have a transformative impact on the way militaries operate.

3D printing technology is revolutionizing the military industry by providing a way to quickly and cheaply produce spare parts, prototypes, and even entire weapons systems. The technology is still in its early stages, but the potential applications for 3D printing in the military are vast and could change the way wars are fought and natural disasters are responded to in the future.

For more information on 3D printers that military branches are utilizing, please visit our shop at shop3duniverse.com.

How the US Military uses 3D Printing Technologies

Learn Blog

How are different branches of the US military using additive manufacturing? Here are some past and present additive manufacturing projects across the US Army, Air Force, Navy, and Marines:

Legacy Parts, On Demand

What happens when aging military equipment and vehicles need parts that are obsolete? This is an ongoing issue faced by all six branches, and a lot of time and effort is being put into finding ways to solve the problem.

  • In 2020, the U.S. Army needed more hatch plugs: devices mounted on combat vehicles to help soldiers see during low-light missions. The original vendor had discontinued the part, and the replacements would require a three-month lead time and cost $10K to produce. The Army used additive manufacturing to solve the problem. In a few short days, they 3D printed two versions of the part using different materials at a fraction of the cost.
  • The Airforce Lifecycle Management Center regularly uses 3D printing to manufacture obsolete parts for a number of legacy fighter jets including fleets of B-52s, the massive C-5M Super Galaxy, and the B-2 Stealth Bomber.
  • The Army Materiel Command (AMCOM) began working with a team from Wichita State University in late 2020 to dismantle and scan every part of a Black Hawk helicopter for 3D printing. Other branches in AMCOM are undertaking a similar task and assessing 48K ground vehicle parts and 98K communications and electronics parts for 3D printing.

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Less (Weight) is More

It’s not unusual for a single soldier to carry between 90 to 140 lbs worth of gear, including weapons, ammo, water, MREs, batteries, and personal protective equipment. That’s a lot to manage, especially in a high-stress situation. And soldiers aren’t the only ones burdened by additional weight. Increased weight in transport vehicles, planes, and ships can decrease fuel efficiency and reduce maneuverability and speed. As a result, the military has a lot of interest in developing ways to lower weight without sacrificing performance.

  • The Army Research Laboratory is currently working on making a variety of new, lightweight vehicle parts — brackets, propulsion systems, weapons, and turret components — with additive manufacturing. They are investigating lightweight metals such as titanium, titanium alloys, and hybrid ceramic tile composites for their Next-Gen Combat Vehicles (NGVC) program.
  • Earlier this year, the Army Research Laboratory partnered with a team at the University of Central Florida to improve the additive manufacturing of a high-strength magnesium alloy by increasing the density enough to make 24 micro-lattice structures. The material has the potential to produce lightweight mission components typically carried and used by soldiers in the field.
  • After a few years of successfully using AM to replace obsolete parts in legacy aircraft, the Air Force has now turned its focus towards rolling out flightworthy hardware for in-use military engines, aircraft, and support equipment. The Air Force is particularly interested in the increased durability and decreased weight of 3D printing with AM materials. After all, less weight means more speed and lower overall fuel costs.

Bigger, Better, Faster

The military has a longstanding interest in using AM technology to quickly create very large, durable parts. The need for bigger items is always greater in the field where vehicle replacement and maintenance or short-term shelters definitely come in handy.

  • Earlier this year, the U.S. DEVCOM Army Ground Vehicle Systems Center (GVSC) launched its Jointless Hull project. As part of this project, the GVSC is developing the largest 3D metal printer in the world to manufacture single-piece hulls and other large parts for military ground vehicles. When complete, the massive 3D printer is expected to print metal items up to 30’ L x 20’ W x 12’ H. There is also a smaller version of the printer in the works for development work to support the larger machine.
  • In late 2019 — and in under 36 hours — members of the U.S. Marines at Camp Pendleton used quick-drying concrete to 3D print a bunker large enough to hide a truck-mounted multiple rocket launcher system.
  • Not to be outdone by the Marines, this year the U.S. Army Corps of Engineers developed a deployable 3D printer that can quickly create shrapnel-resistant concrete structures like buildings, small bridges, bunkers, and gatehouses.
Rugged, durable 3D printers can be deployed to print parts as needed at remote locations.

Printing in the Field

In an effort to move from form to function, all branches of the U.S. military are exploring more efficient and effective ways to 3D print anywhere in the field whether on board a ship at sea or at a remote base camp.

  • The U.S. Navy and Naval Sea Systems Command (NAVSEA) are exploring ways to use AM to design, print, approve, and install critical or obsolete parts while at sea. This will allow crews to 3D print parts and tools on-demand to reduce part production costs and repair time. A recent example can be seen aboard the USS Tulsa where Navy sailors now have access to 3D printing technology and, thanks to training provided by the Robert C. Byrd Institute at Marshall University, they know how to use it. The crew members were taught how to set up, operate, and maintain 3D printers. They were also taught computer-aided design techniques and how to use precision scanning equipment. Once at sea, they will have the opportunity to practice their new skills on the ship by 3D printing various components.
  • Meanwhile, across the pond in France, the Marine Nationale (French Navy) launched the largest 3D printed metal propeller installed on an in-service military ship in January of this year.
  • Researchers at the Army Research Laboratory (ARL) have taken recycled polyethylene terephthalate (PET) from leftover bottles and plastics and used it as a material in a fused filament fabrication (FFF filament). Eventually, the plan is to let U.S. forces 3D print replacement parts on demand while in the field using discarded battlefield plastic waste like water bottles, milk jugs, and more.

* For more about the Air Force and its use of additive manufacturing, take a look at one of our earlier blog posts, Additive Manufacturing with Composites in Aerospace and Defense.

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3D printers in military service - big overview

Overview: 3D printers in military service.

Source: https://all3dp.com/

The military industry has always been at the forefront of progress: many inventions either began their life as military or dual-use products, or, in the very first years after their appearance, were involved in this area . In this age of digital technology, this fate has not escaped 3D printing.

3D printers are actively used by military contractors and direct employees of all branches of the military. nine0009 In this article, we will talk about the use of 3D printing in the military-industrial complex around the world: from providing military equipment with spare parts, to operational printing of drones and buildings anywhere in the world.

In Russia,

JSC "Federal Research and Production Center "Titan-Barricades", which develops missile systems and military vehicles, has bought and uses in prototyping a kit based on an XJRP SPS450B 3D printer. The kit consists of two devices: directly a 3D printer with a large print area, working on SLA technology, and a polymer curing chamber. nine0009

XJRP SPS450B 3D Prototyping Kit.
Source: http://pechat3d.ru/

The 3D printer is planned to be used to create miniatures of future parts, cases or mechanism assemblies. The first product made on this 3D printer was a prototype wheel with a tread.

Ilyushin specialists plan to produce some simple parts for the Il-112V military transport aircraft using 3D printing. nine0003

Model of the Il-112V transport aircraft.
Source: © ITAR-TASS

Together with specialists from the Voronezh Aircraft Plant (VASO), PJSC Il specialists use 3D-printed parts as test samples, which will be replaced with originals made by the classical method before departure. But in the future, it is planned to master the printing of simple components that will be installed on mass-produced aircraft. nine0003

Pavel Chernikov, First Deputy General Director of PJSC Il, said: “The IL-112V is being created from scratch, and many parts and components need to be improved during installation on the aircraft. We started using a 3D printer to see how right or wrong our calculations were. Such technologies make it possible not to interrupt the finalization of finished products, which, in turn, significantly reduces the installation time of equipment and reduces the cost of the production process.”

Research and Production Corporation "Uralvagonzavod" named after F. E. Dzerzhinsky purchased a 3D printer S-Max manufactured by ExOne. nine0003

ExOne S-Max 3D printer.
Source: http://3dtoday.ru/

This printer is designed for making sand molds. Molds are used for casting metal blanks. As the deputy chief metallurgist of NPK Uralvagonzavod said: “We will no longer have to manufacture expensive foundry equipment for experimental, new products and complex castings of small series. It will be enough for a designer to develop a 3D model of the required casting, according to which, also in 3D, the mold is made. The finished cores will go to the foundry. In addition, they can be transported to solve the problems of the corporation over any distance." nine0003

A sand mold produced by the S-Max 3D printer, used for casting metal blanks.
Source: http://3dtoday.ru/

This is not the first professional 3D printing system that Uralvagonzavod uses. In 2015, the company purchased a Fortus 400mc 3D printer manufactured by Stratasys Corporation. This printer is used in the production of parts for the T-14 "Armata" tank and other vehicles manufactured by Uralvagonzavod. nine0003

Tank T-14 ("Object 148") on the platform "Armata".
Source: OAO NPK Uralvagonzavod

Representatives of the enterprise note that the introduction of 3D printing saves time and production resources. It is not required to spend forces on turning metal samples. If a part doesn't fit, it's easier to reprint it than remake it.

Russian Helicopters Holding, according to its CEO Andrey Boginsky, plans to 3D print about a hundred parts for rotorcraft by 2020. nine0003

Andrey Boginsky.
Source: © Yuri Smityuk/TASS

In 2018-2019, it is planned to conduct a series of bench tests in order to obtain all the necessary certificates for printed parts by mid-2020. In total, it is planned to test about a hundred parts and assemblies.

Compared to traditional parts, 3D-printed parts are lighter and their production will be deployed at the Kazan Helicopter Plant. As a result of the use of parts obtained by 3D printing, the holding plans to reduce the cost of products. nine0003

In the world

The road of army 3D printing is not paved with roses. When we hear about cool 3D printed military projects, we have to consider some of the challenges that come with doing them.

Soldiers get acquainted with FORTUS.
Source: https://all3dp.com/

Quality certification problem. Many things that the army is supposed to produce using 3D printing are designed for harsh operating conditions, they are subject to high requirements for compliance with dimensions, geometry and quality, and an unsuccessfully printed part can lead not only to monetary losses, but also to the death of soldiers . This issue will most likely be resolved by certification of the 3D printers themselves. nine0003

Insufficient printing speed for the army. Even the most expensive 3D printer is not fast enough. There are also issues of privacy/security, copyright, and many other little things that are not obvious at first glance.

While these issues are being addressed, the US Department of the Navy has decided to host a 3D printing hackathon. 12 organizations were invited to participate, which showed their developments in the field of 3D printing for the Navy. According to the participants, fully or partially printed inventions: “Allow to improve the ability to maintain combat readiness.” nine0003

One of the new and memorable developments was the four-legged transporter robot (MeRlin). It turned out to be quite compact and can run, jump and walk up and down stairs. Three-dimensional printing made it possible to create, right in the supporting frame of the robot, a hydraulic manifold that serves to transfer energy to the robot drives. Those interested in robotics will find Merlin similar to the transport robots of Boston Dynamics.

The device of the robot MERLIN (Merlin).
Source: https://all3dp.com/

Aviation

A 3D-printed drone was launched from one of the British Royal Navy ships at sea, HMS Mersey. The device was created in collaboration with the University of Southampton.

Launch of a 3D printed drone. nine0021
Source: https://all3dp.com/

Body made of nylon, laser sintered. With a wingspan of one and a half meters, the drone weighs only three kilograms. The main task of this project was to create a small drone for exploring the surroundings, which can be quickly printed on board the ship.

The drone, named SULSA, was equipped with a small video camera. Management was carried out by researchers from Southampton using video cameras. The flight, with a range of 500 meters, lasted only a few minutes, but proved that 3D printed drones could be launched from the sea. nine0003

The route of the SULSA drone during a test flight.
Source: https://www.southampton.ac.uk/

3D printing solves the problem of ship capacity by allowing equipment to be printed at sea as needed. The only thing you need to have on board to print a drone is a 3D printer and a supply of nylon, which is disproportionately cheaper than a case made using traditional technologies, and takes up much less space. nine0003

The only drawback is the print speed, but it is expected to improve in the near future. Engineers from the American Army Research Laboratory (ARL) are trying to fight this shortcoming. They are developing drones that can be made within a day. Engineers are building drones that can be used to assist soldiers in communication, delivery, and aerial surveillance.

Eric Sopero demonstrates his drone to US military personnel. nine0021
Source: https://all3dp.com/

Drones are made using off-the-shelf motors and propellers, but their body is almost entirely 3D printed. The maximum speed of the drone is 55 miles per hour. Drones can either be controlled by the operator from the remote control or operate in a completely autonomous mode. Work continues to reduce noise and increase flight range, maneuverability and payload.

The US Army is partnering with the Marine Corps to develop an unmanned vehicle parts catalog that can be downloaded to an employee's tablet. The software of this catalog allows you to order or 3D print a product directly from it. nine0003

American soldier with a drone.
Source: https://all3dp.com/

In addition to experiments with drones, 3D printing is also used in “big” aviation.

For example, the US Air Force has announced that it will 3D print toilet seats for military transport aircraft. The announcement comes after a scandal erupted when it was reported that each toilet seat cost the Air Force $10,000 to replace. nine0003

Airplane seat for $10,000.
Source: https://all3dp.com/

The public, which already believed that the government did not always save on military spending, was extremely outraged. After an investigation initiated by one of the senators, the military department announced that it would print toilet seats on 3D printers.

Why is the toilet lid so expensive? These covers were mass-produced by Lockheed Martin, and in 2001 this giant of the military industry stopped their production. In addition, the military department explained that the C-5 toilet seat is not only a cover, but also part of the lavatory wall, which is designed to protect the body of the aircraft from corrosion that can be caused by urine. nine0003

According to the manufacturer, its high cost is due to the need to suspend the production of other goods. In the case of independent production of the Air Force, the spare part will cost only $300.

The manufacturer now claims that the US Air Force does not own the copyright to this cap. It is not known how this lawsuit will end, but the Air Force says that they will no longer buy this spare part, because they can make it themselves much cheaper.

As stated by the department: “The use of 3D printing allows us to create parts that are no longer being produced, resulting in significant cost savings. ” nine0003

C-5 transport aircraft.
Source: https://all3dp.com/

Another example of 3D printing was demonstrated by the Maryland Marines. Using 3D modeling and 3D printing, they made a $70,000 F-35 fighter jet part for just 9 cents. The Marines were assisted by Sam Pratt, a mechanical engineer in the design office of the Carderock Additive Technology Factory. nine0003

Sam revealed that he was with a support platoon in South Korea teaching CLB-31 Marines how to design 3D models and how to use 3D printing. His main task was to test the performance of 3D printers on marine vessels. He also taught employees how to use Solidworks CAD.

Sam Pratt talks to the Marines about 3D printing.
Source: https://all3dp.com/

When there was a problem printing a part needed to repair an F-35, a Marine officer offered to team up to cooperate. It turned out that the employees had already developed this part, but could not find the right dimensions. The fact is that they used a hobby-grade 3D printer and the free 3D editor Blender - Blender is ideal for implementing art projects, but it is difficult to create engineering products in it.

American Marine at the 3D printer.
Source: https://all3dp.com/

Pratt helped with modeling and printing issues, the part was printed in PET-G.

Currently there are about 90 parts for ground vehicles that are approved for 3D printing in the military, you can download one of these parts and print it.

Large manufacturers are also moving forward and mastering 3D printing technologies. Thus, the giant of the aviation and military industry Lockheed Martin is actively investing in 3D printing. nine0003

Lockheed Martin uses 3D printing in its manufacturing processes, with over a hundred 3D printers in its arsenal for prototyping, tooling and printing finished products.

There are several reasons why Lockheed Martin uses 3D printing:

  • Reducing the time of production of products - up to 80%;
  • Reducing the weight of parts - up to 40%;
  • Proven reliability of parts in difficult conditions;
  • The most important thing is the possibility of an additional increase in production in the near future. nine0388

For example, it takes 18 to 20 months to manufacture fuel tanks for spacecraft using traditional technologies. The production of such a tank by 3D printing takes two weeks. In this case, a better uniformity of the structure of the tank elements is achieved. The tanks are manufactured using a Sciaky printer using EBAM (Electron Beam Direct Manufacturing) technology, in which a bar of metal material is heated by an electron beam.

nine0021
Lockheed Martin uses 3D printing in its manufacturing processes.
Source: https://all3dp. com/

Lockheed Martin's 3D printed products have already passed the lab testing stage and are in active use. Some of them travel around our solar system: the Jupiter-exploring Juno satellite has eight 3D-printed brackets, and the Orion spacecraft uses printed high-pressure valves. nine0003

Fleet

South Korea is 3D printing loudspeaker grilles for aircraft carriers. Shipping these gratings from Europe took up to seven months and cost $612 each. The printed part is made in 4-5 hours and costs about $35. Printing parts reduces their cost and production time, and localization of production reduces dependence on foreign supplies, which may be delayed or become unavailable for various reasons.

General Electric has contracted with the US Navy to develop software for rapid 3D printing of spare parts for ships, aircraft and other critical military installations. The contract, worth nine billion dollars, is designed for four years and provides for the creation of technology "digital duplicates" - a complex of software, base models and hardware. This technology will be used both for those spare parts that are no longer manufactured, and for new parts of ships and aircraft. nine0003

Concept Laser M2 3D printer printing with metal powder.
Source: https://all3dp.com/

The project is being implemented in two stages: at the first stage, software and hardware parts will be developed, at the second stage they will be combined into a complex capable of quickly creating the necessary products using laser metal melting technology (DMLM).

Ammunition and small arms

The US Army has designed and 3D printed a fully functional grenade launcher called "R.A.M.B.O". The development of the grenade launcher took about six months. He fires 3D printed grenades

R.A.M.B.O. grenade launcher
Source: https://all3dp.com/

The grenade launcher consists of 50 parts, all of which, with the exception of springs and hardware, are printed on a 3D printer. nine0003

3D printed parts of the R.A.M.B.O.
Source: https://all3dp.com/

R.A.M.B.O. demonstrated characteristics similar to the M203 underbarrel grenade launcher made in the traditional way.

A US Marine team is 3D printing and testing small explosive containers that can be used on the battlefield. nine0003

3D printed container for explosives.
Source: https://all3dp.com/

The development of small arms began in the private sector, with the most primitive pistols. On the Internet, you can find drawings of products such as the sensational Liberator. The first 3D printed pistol was printed on a professional Stratasys Dimension SST printer. The gun is chambered for 9 caliber rounds.mm and is charged during assembly.

A gun whose main components are made of plastic and printed using a 3D printer. Frame: YouTube.
Source: YouTube

The very possibility of obtaining weapons using 3D printing so excited the public that the drawings of the "Liberator" were withdrawn from public access, and the United States introduced a ban on 3D-printed weapons. nine0003

Solid Concepts has created a replica of the .45 Browning M1911 pistol, the Solid Concepts 1911 DMLS, using selective metal laser sintering. The first sample withstood 50 shots, later ones are capable of firing 600 shots without visible damage.

A working replica of a .45 Browning pistol M1911 - Solid Concepts 1911 DMLS, made by selective metal laser sintering. nine0021
Source: Solid Concepts Inc

Recently, the ban on the distribution of 3D printed weapons was lifted by a court decision. So, it is now possible to print weapons in the USA, with some restrictions: they can be no more than 50 mm in caliber and models cannot be freely available. This ban was easily circumvented by Defense Distributed, which posted models of their rifle for sale on one of the online services.

M4 rifle from Defense Distributed.
Source: https://depositphotos.com/

“Our models are not in the public domain because customers pay money for them,” a company spokesman said.

Uniforms and protection

The Vatican decided to use 3D printing technology for the production of traditional Swiss Guard headdresses. nine0003

Swiss Guard.
Source: https://all3dp.com/

The Swiss Guard is the personal bodyguard of the Pope. From time immemorial, their form was made of metal, but now they have decided to keep up with the times. A 3D printed helmet will be significantly cheaper and, more importantly, lighter.

3D printed helmet prototype.
Source: https://all3dp.com/

The helmets are made of PVC and bear the coat of arms of Pope Julius II, who founded the Swiss Guard in 1506.

The US military turned to the creators of the Iron Man costume, a movie character, for help in creating uniforms for the soldier of the future. The military commissioned Legacy Effects to develop and print the prototype components for the TALOS Special Outfit Kit. nine0003

TALOS will contain a cooling system to maintain a comfortable temperature in the suit, a tactical display and an integrated exoskeleton.

The concept of the uniform of the future - a set of special uniforms TALOS.
Source: http://3dprintingindustry.com/

The studio team will join the large team already working on the project, which includes bioengineers, combat veterans and technologists. nine0003

Building

The US Army Research Engineering Team printed a large building in just 21 hours. The area of ​​the building is 47.5 square meters. The barrack-style building is the result of a three-year US Army Construction Engineering Research (ACES) program with a laboratory in Champagne, Illinois.

3D printed barracks.
Source: https://all3dp.com/

Such a short construction time means that such temporary structures will become more affordable with the development of 3D printing. These buildings can be used as housing for refugees or temporary housing in case of natural disasters.

The process of building a 3D printer.
Source: https://all3dp.com/

The building looks like an ordinary house, but in the future such buildings can be given any look. Such buildings are also more energy efficient than traditional ones - they require less energy for heating and cooling.

ACES cuts the amount of building materials used in half. Reducing the need for labor is 62%, compared with the construction of plywood structures.

Laying concrete mix with a construction 3D printer. nine0021
Source: https://all3dp.com/

ACES allows buildings to be printed using local materials.

Self-Sufficiency

A collaboration between the US Army Research Laboratory and the Marine Corps has led to the development of a technology to produce 3D printed PET filament from plastic waste such as water bottles.

According to the military, water bottles and plastic packaging are the most common litter on the battlefield. Both US and allied forces produce large amounts of this waste, and the ability to recycle it will reduce the cost of transporting raw materials. The filament obtained from recycled materials, provided that it is properly cleaned and dried, is completely equivalent in tensile strength to its analogue from primary raw materials. nine0003

Joint work of employees of the Research Laboratory of the US Army and the Marine Corps.
Source: https://all3dp.com/

A plant is being developed, housed in a standard shipping container, that will allow the production of filament from waste.

The US Army is also developing food printers. Their advantages are obvious:

  • the possibility of reducing the cost of food, compared with the traditional delivery of rations from abroad;
  • the possibility of compiling an individual menu, in accordance with the preferences of each soldier;
  • the possibility of individual balancing of the diet, depending on the dietary needs of each soldier.

The printer, like classic 3D printers, stacks components in layers.

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3D printed food.
Source: https://all3dp.com/

The printer uses the ultrasonic agglomeration method to 3D print small snacks.

Electronics

Researchers at the University of Massachusetts Lowell have developed a new way to 3D print conductive components for radar systems. They have created a new type of ink that allows radars to be made using 3D printing. nine0003

Electronic components obtained by 3D printing.
Source: https://all3dp.com/

The development was sponsored by Raytheon, one of the defense industry companies.

According to the developers: “The use of this technology makes it possible to obtain cheaper and more versatile systems than those obtained by classical methods. This technology has obvious advantages in the military sphere, but it can also be used in civilian industry, for example, in the production of weather stations or unmanned vehicles. The main problem was obtaining ink with desired properties, capable of working with high-frequency radiation.” nine0003

Applying ink to a plastic plate.
Source: https://all3dp.com/

The 3D printer is equipped with two heads with different operating principles. One applies the ink by spraying, the second fixes them by microvibration. Radar system components such as a voltage controlled capacitor (varicap), phase shifter (for electronic control of phase array radar systems) and frequency filters can be manufactured using this technology. nine0003

The ink material is based on nanoparticles that can be injected into molten plastic and then solidify with it, creating conductive structures.

The US Air Force Research Laboratory teamed up with American Semiconductor to create a silicon-polymer memory chip.

Using 3D printing technology, they have developed a new ultra-flexible chip with built-in sensors.

Dan Berrigan holding the new flexible chip.
Source: https://all3dp.com/

According to American Semiconductor, the thickness of the silicon wafer is 2000 angstroms. This tiny chip can measure humidity levels, temperature, muscle fatigue, and so on. This makes it ideal for use in new technologies for monitoring the well-being of wounded soldiers or the elderly.

Flexible electronics technology is being developed not only by research laboratories, but also by industry giants. nine0003

Apple, Boeing and the Massachusetts Institute of Technology formed an alliance to collaborate with the US Department of Defense in the field of flexible electronics.

The goal of the alliance is to have high quality flexible electronics by 2020.

The Department of Defense plans to provide a consortium called the FlexTech Alliance with $75 million over 5 years and raise $96 million in additional funding.

Smart clothes.
Source: https://all3dp.com/

The consortium includes 96 companies, 11 specialized laboratories, 42 universities and 14 state and regional organizations. The key partners of the consortium are Apple, Boeing, General Electric, General Motors, Lockheed Martin, Motorola Mobility, Qualcomm and many others. Partner universities include Cornell, Harvard, Stanford, New York University and the Massachusetts Institute of Technology. nine0003

Practical applications will be primarily focused on military targets, such as uniforms with vital sign monitors. Pressure sensors can also be installed on vehicles to monitor deformation in key areas.

The civilian application of such microcircuits will help athletes control body function and improve performance, and people suffering from cardiovascular disease, control and prevent seizures. This technology will allow hospitals to monitor their patients en masse. nine0003

Concepts or Looking Ahead

British scientists and engineers are working on growing military drones using chemical technology.

Hydroponic chemputter.
Source: https://all3dp.com/

Military developers explore all possible and impossible technologies. In this case, they are working on a "chemcomputer". “Chemputer” is a registered trademark of BAE Systems. The technology is being developed by Professor Lee Cronin of the University of Glasgow and is a 3D printing of biomaterial drones and aircraft. nine0003

Unlike classic 3D printers, a chemputter performs chemical reactions at the molecular level, creating everything from electronics to wings.

Drone prototypes.
Source: https://all3dp.com/

While British scientists are inventing new technologies in printing for the military department, simple makers are creating weapons of the future using conventional 3D printers. nine0003

So, David Wirth created a hand railgun in his workshop.

David Wirth with his railgun.
Source: https://all3dp.com/

Possibly inspired by the computer game Quake, he created this weapon using CAD, a 3D printer and an Arduino platform. The railgun can use aluminum or graphite bullets as ammunition, firing them at a speed of 250 m/s. The design is based on six huge capacitors, which, with a total weight of about nine kilograms, store more than 1800 joules of energy for each shot. The railgun also consists of batteries, two parallel contact rails and a pneumatic ammunition supply system. nine0003

Diagram of a railgun by David Wirth.
Source: https://all3dp.com/

Conclusion

3D printing technology is increasingly used in the military. The main role in its promotion is played by the need to reduce costs. On-site 3D printing of parts helps to solve the problems of logistics and supply, allowing you to save time and money on delivery, which is important for the army and aviation, and even more so for the navy - it is impossible to foresee ashore and take with you everything that you might need, and delivery boarding at sea is expensive. nine0003

We have cited only a small part of the military cases as examples - it is impossible to describe in one article all the prospects for the use of 3D printing in the military industry. And most of the solutions used by the military in production are also relevant for the civilian sector.

You can buy a 3D printer for production in Top 3D Shop — our experts will help you choose the best equipment for solving any tasks.

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The US Army will use a 3D printer to print parts.

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Information nine0003

The US Army will use a 3D printer to print spare parts.

Scientists have found a way to reuse waste to make filament that is durable and suitable for a 3D printer.

The reason for introducing additive manufacturing is that it reduces the weeks of waiting for vital items. According to preliminary designs, it was found that replacement elements could be printed on the base in just a few hours.

For example, waste such as plastic bottles can be recycled into fine 3D printing filament. But not only bottles are recyclable. Cardboard is also valuable as a composite when combined with plastic. nine0003

Nicole Zander, PhD, says: “Ideally, you won't have to wait for the next truck to bring parts. Instead, you can collect plastic, milk cartons, cartons and other items and then use them as raw materials for 3D printers.”

This work was presented at the 256th National Meeting and Exhibition of the American Chemical Society (ACS).

Cellulose-reinforced recycled PET and PP 3D printed parts.

US Army lab researchers quickly discovered that the use of polyethylene terephthalate (PET) works well as a raw material for 3D printers. It can be recycled from containers in which water is supplied to army bases. In fact, they found that the PET filament produced was just as strong and flexible as the commercial one. To test it, they printed the car's radio control bracket, a part that usually takes a long time to change using traditional production. With the help of 3D printing, this process was reduced to two hours. nine0003

Having tested PET containers, the researchers turned their attention to polypropylene (PP) and polystyrene (PS). These ingredients can be found in food containers and disposable cutlery.

Initial results indicated that these plastics were not particularly useful. However, when they are mixed with other plastics, their properties are improved. Also mixed cardboard, wood fibers and other cellulose waste to create composite threads.

Composite PP/cellulose 3D filaments were formed using a process called solid state grinding. It involves grinding polyethylene, paper, or wood flour in a twin screw extruder to form a powder, which is then melted and used by a 3D printer.

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