3D printing increasingly recommended by defence sector for potential savings of £110 million

The world of aerospace manufacturing is undergoing a significant transformation, with countries like the US and the UK leading the charge in adopting additive manufacturing (AM) technologies. This shift promises to strengthen supply chain resilience and revolutionize the way critical aerospace technologies are produced.

In the US, the military has already demonstrated the rapid deployment of 3D-printed drone systems, built and deployed in under 24 hours. This rapid innovation showcases the potential of AM to streamline production processes and respond quickly to evolving military needs.

Across the pond, a consortium led by Honeywell has received UK government funding for a project aimed at leveraging AI and AM to revolutionize UK aerospace manufacturing. This project is a testament to the UK's commitment to harnessing the power of AM for national growth and competitiveness.

However, the defence sector in the UK is yet to fully capitalize on these transformative capabilities offered by AM. A critical knowledge gap exists between the industry and procurement teams, making it challenging for decision-makers to fully comprehend the potential of modern AM applications.

Craig Pyser, chairman of AMUK and CEO of Portsmouth-based additive manufacturer AMufacture, emphasizes the importance of bridging this knowledge gap to unlock the estimated £35.5m annual benefits from AM. Pyser also highlights the potential net financial benefit of £110m over the next 15 years if 15% of the defence inventory were additively manufactured, as outlined in the MoD's own strategy.

Companies like AMufacture, Renishaw, 3T RPD, and Metalysis in the UK are already providing industrial-scale 3D printing services and have deployed these technologies for customers in various sectors, including aerospace, automotive, medical, and marine.

Moreover, UAV and drone components represent a particularly compelling application for AM. The challenge isn't the technology itself but rather the unfamiliarity of decision-makers with these modern AM applications.

Notably, Lockheed Martin is upgrading the Republic of Korea Air Force's F-16 Block 52 flight simulators to mirror the advanced capabilities of its modernised F-16 Viper (F-16V) aircraft. Meanwhile, Boeing has launched its new Engineering Center within the Cici & Hyatt Brown Center for Aerospace Technology at Embry‐Riddle Aeronautical University's Research Park.

To further strengthen their engineering capabilities, Brookhouse Aerospace has invested over £500,000 in additional machinery, while AMufacture has invested significantly in advanced HP Multi Jet Fusion printer technology and automation.

Dassault Systèmes has also announced that the NCC has adopted the 3DEXPERIENCE platform on the cloud and extended its use to other innovation centres within the UK High Value Manufacturing Catapult network.

As the MoD shifts from 'just-in-time' to 'just-in-case' supply chain models, there is an urgent need for education about modern AM capabilities. By bridging the knowledge gap and embracing AM, the defence sector can unlock significant financial benefits and position itself for a more resilient and innovative future.