The defence sector is undergoing a paradigm shift, driven by the urgent need for operational agility and supply chain resilience. At the heart of this transformation is additive manufacturing (AM), a technology that is rapidly moving from prototyping to mission-critical applications. The shift is not just about adopting new tools, but about rethinking the entire defence manufacturing ecosystem.
The traditional model of centralised production and lengthy supply chains is increasingly vulnerable to geopolitical disruptions, trade restrictions, and raw material shortages. The lessons of the COVID-19 pandemic have underscored the risks of over-reliance on single-source suppliers and extended logistics networks. Today, defence operators cannot afford to wait weeks for critical components when a fighter jet failure occurs at a forward operating base. The stakes are too high, and the operational tempo too demanding.
Additive manufacturing offers a compelling solution. It enables on-demand production of components, virtually anywhere and anytime, ensuring operational readiness in contested environments. “We’re no longer just talking about prototyping or small-batch production,” a senior defence contractor recently noted. “We’re seeing additive manufacturing become integral to mission-critical systems and battlefield readiness strategies.”
The benefits of AM extend far beyond de-risking supply chains. It enables rapid innovation and agility that traditional manufacturing cannot match. For legacy systems, AM can recreate components on demand, ensuring the continued operation of aging fleets. Complex geometries, impossible to produce conventionally, can be manufactured with AM, enhancing performance and efficiency. Moreover, AM allows for digital sovereignty, where technical data packages can be transmitted securely and produced locally, eliminating vulnerable physical supply chains.
Field resilience is another critical advantage. Regional AM Support Centres can repair damaged equipment in days rather than weeks, dramatically improving mission readiness. This capability transforms operational planning, allowing commanders to sustain operations with a smaller logistics footprint. Cost-effectiveness is also a key factor, as AM reduces energy consumption, minimises transportation requirements, and decreases material waste.
The applications of AM in defence are diverse and impactful. Saab, Sweden’s defence leader, has successfully implemented AM parts for their Gripen fighter jets as temporary replacements, keeping aircraft operational until regular maintenance. In the unmanned systems domain, topology-optimised drone frames produced through AM are delivering substantial performance gains, reducing weight while maintaining structural integrity, and extending flight times and payload capacity.
Materials innovation is another area where AM is making strides. EOS, a leader in industrial 3D printing, has developed EOS CopperAlloy CuNi30 for maritime applications in partnership with Phillips Federal and Austal USA. This corrosion-resistant alloy mitigates casting delays, allowing critical naval parts to be produced in a fraction of the time. Even personal defence equipment is being transformed, with advanced suppressors for military firearms produced through AM offering decreased blowback, increased durability, and enhanced noise reduction.
Despite these compelling use cases, defence organisations still face challenges in adopting AM. Certification processes are a significant hurdle, with defence authorities working to develop standards specific to AM. Concerns about the microstructure of AM parts and intellectual property protection also persist. However, innovations like secure digital rights management systems are addressing these issues, allowing for the safe and efficient sharing of sensitive military designs.
The imperative for defence manufacturing leaders is clear: the question is no longer whether to adopt additive manufacturing, but how quickly they can integrate it into strategic operations. Those who move decisively will gain substantial advantages in operational flexibility, innovation capacity, and battlefield readiness. The future belongs to those who can adapt fastest. For the defence sector, additive manufacturing is not just another production method; it is the foundation of a more resilient, responsive, and capable military industrial base that can meet the challenges of an increasingly complex and contested global security environment.
