Manufacturing sector in defense urged to incorporate 3D printing for estimated £110 million cost reduction

In the ever-evolving world of defence manufacturing, a significant shift is underway as innovative technologies are reshaping the industry. This transformation is particularly evident in the growing adoption of additive manufacturing, a cutting-edge approach that promises to revolutionise the way defence systems are designed and produced.

AMufacture, a UK-based additive manufacturer co-founded by Craig Pyser and Will Howden, has invested heavily in advanced HP Multi Jet Fusion printer technology and automation. This investment is set to bolster the company's capabilities, positioning it at the forefront of the additive manufacturing revolution.

Meanwhile, Lockheed Martin Skunk Works and BAE Systems FalconWorks have formed a strategic partnership to jointly develop a new generation of uncrewed autonomous air systems. This collaboration underscores the potential of additive manufacturing in defence applications, with UAV and drone components representing a particularly compelling application. Rapid iteration and on-demand production can provide tactical advantages, making additive manufacturing an attractive proposition for defence contractors.

Boeing has also made a significant move in this direction, launching a new Engineering Center at Embry-Riddle Aeronautical University's Research Park. This centre reinforces Boeing's long-term investment in the region and signals a commitment to the advancement of additive manufacturing technologies.

Woodward Inc, a global leader in energy control solutions, has announced plans to build a precision manufacturing facility in Greer, South Carolina. This facility is set to leverage additive manufacturing capabilities, further demonstrating the sector's growing importance.

Pratt & Whitney, a subsidiary of RTX, has secured an $18m contract from the NATO Support and Procurement Agency (NSPA) to sustain TF33 engines. This contract underscores the potential of additive manufacturing to support existing defence infrastructure, providing a critical bridge between traditional manufacturing methods and the new technologies.

However, there are challenges to be addressed. Experts have noted that the sector's unfamiliarity with modern 3D printing applications is blocking access to production-ready capabilities. This knowledge gap between the industry and procurement teams commissioning large-scale defence contracts is a critical issue that must be addressed to fully realise the benefits of additive manufacturing.

The UK defence sector is not immune to this challenge. Craig Pyser, chairman of AMUK, has warned that the Ministry of Defence's new Advanced Manufacturing Strategy highlights additive manufacturing as critical for strengthening supply chain resilience. If this knowledge gap can be bridged, the MoD stands to reap significant benefits, with a Defence Innovation Unit report estimating that if 15% of the defence inventory were additively manufactured, the net financial benefit to the MoD would be £110m over the next 15 years.

The UK's additive manufacturing sector is not lacking in talent. British companies like 3T Additive Manufacturing Ltd., based in Thatcham and specializing in large metal 3D-printed parts for aerospace, medical, and automotive industries, are already active in producing large additive manufacturing parts and could support the armed forces supply chain. Rapid Fusion, based in Exeter, has also developed large format hybrid 3D printing technology, which may be relevant for large additive manufacturing needs.

The government's commitment to increasing defence spending, with a planned £2.9bn increase in 2024 and a goal to reach 2.5% of GDP by 2027, provides a promising backdrop for the growth of additive manufacturing in the defence sector. As the industry continues to evolve, it is clear that additive manufacturing will play a crucial role in shaping the future of defence manufacturing.

In conclusion, the adoption of additive manufacturing in the defence sector presents a significant opportunity for transformation. With strategic partnerships, investments in technology, and a commitment to bridging the knowledge gap, the industry is poised to reap the benefits of this revolutionary technology. The future of defence manufacturing is additive.

Manufacturing sector in defense urged to incorporate 3D printing for estimated £110 million cost reduction