The US Air Force has awarded 3D Systems an additional $9 million to continue developing a metal 3D-printing system for aerospace components.
The US Air Force has awarded 3D Systems an additional $9 million to continue developing a large-format metal 3D-printing system for aerospace components.
The award extends the Large-Format Metal 3D Printer Advanced Technology Demonstrator program for another two years, bringing total funding for the initiative, launched in 2023, to $27.4 million and supporting its final demonstration phase.
Under the program, 3D Systems is examining whether additive manufacturing can produce large metal components for high-temperature, high-speed aerospace applications.
Unlike conventional manufacturing, the process builds components layer by layer from digital designs, potentially allowing complex parts to be made with fewer separate pieces.
3D Systems is developing its direct metal printing platform to manufacture large components that could eventually be used in flight-critical applications.
Work will continue at the company’s facilities in San Diego, California, and Rock Hill, South Carolina.
US Military Broadens Use of 3D Printing
The US military is expanding its use of additive manufacturing, applying the technology to the development of components, repairs in operational settings, and the construction of military infrastructure.
In July, the US Army opened the first two of 10 concrete-printed barracks at Fort Bliss, Texas.
The buildings will provide accommodation for up to 560 rotating service members, with the entire project scheduled for completion in September.
In April, Naval Air Systems Command awarded Colibrium Additive a $31-million contract to support the qualification of 3D-printed metal components for naval aircraft.
The company will develop manufacturing data for six metal-alloy processes, deliver four printing systems, and train navy personnel, helping establish repeatable methods for producing parts that meet aviation certification requirements.
In 2025, US Air Force and Marine Corps maintainers in Japan used additive manufacturing to replace a damaged cooling duct on an F-15.
The teams printed, delivered, and tested two prototypes within 12 hours, allowing the aircraft to return to service months earlier than initially estimated.
