Additive Manufacturing

The European Space Agency’s in-orbit metal 3D-printing demonstrator has produced its fifth sample aboard the International Space Station, which the German Aerospace Center and ESA’s ESTEC are evaluating. The technology demonstration is not a solicitation, but its testing of part quality and operations in a crewed environment may inform future space-manufacturing requirements and supplier capabilities.

The U.S. Army flight-tested a Group 3 VICTOR unmanned aircraft using a 3D-printed, heavy-fuel rotary-engine series-hybrid propulsion system. The demonstration points to potential follow-on needs in propulsion development, additive manufacturing, aircraft integration, and testing, but no solicitation, award, or contract value was reported.

Snowbird Technologies used its SAMM Tech platform aboard USS Essex and at Schofield Barracks during RIMPAC 2026 to produce seven metal components on demand. The company reported cost advantages for four parts and about 692 procurement hours avoided on one order, offering a sustainment-market signal but not an announced Navy solicitation, award, or funding commitment.

DEVCOM’s Army Research Laboratory demonstrated a 3D-printed heavy-fuel rotary engine paired with a 400-volt motor-generator aboard the Group 3 VICTOR unmanned aircraft near Huntsville. Research findings have transitioned to industry for maturation, signaling potential follow-on integration work—but no solicitation, award, funding amount, or procurement timeline is identified.

Nikon Advanced Manufacturing received a DoD award under the Cornerstone OTA and IBAS program to deliver large-format laser powder bed fusion systems for Tomahawk mid-body production at its Long Beach, California facility. No contract value, delivery schedule, or open solicitation was disclosed, marking this as an industrial-base capacity investment rather than a current bidding opportunity.

NAVSUP Weapon Systems Support issued RFI N0010427RZ058 to assess supplier capabilities for additive manufacturing across 129 candidate naval parts and gather input on future contract pricing and evaluation methods. Responses are due November 2, 2026; this is market research, not a solicitation or award, and SUBSAFE items may be considered in a later phase.

Oak Ridge National Laboratory has unveiled an innovative controller for large-scale composite 3D printing. Funded by the Department of Energy, this technology showcases real-time temperature monitoring and print speed adjustments, signaling future procurement avenues in advanced manufacturing processes.

AML3D has been awarded a AU$0.5 million contract with Austal USA to manufacture critical components for US Navy submarines. This reflects the growing trend toward additive manufacturing technologies within defense supply chains, with significant implications for future procurement strategies.

The Department of Defense has awarded Stratasys $7.8 million to enhance quality assurance for additive manufacturing. This initiative aims to integrate in-situ monitoring, improving production efficiency and reducing costs, which will influence future procurement operations in defense manufacturing.

The U.S. Department of Defense has chosen Norsk Titanium for a 12-month project under the JAQS-SQ program to qualify its RPD technology for titanium alloy products. This initiative aims to bolster the domestic supply chain and improve defense material resilience while also engaging Norsk Titanium in maritime applications through a separate $4.2 million contract.

X-Bow Systems has been awarded over **$280 million** in contracts by the **Pentagon** to enhance its solid rocket motor production capabilities. This investment emphasizes a transition towards **additive manufacturing** for hypersonic weapons, creating significant opportunities for supply chain partners.

The Naval Surface Warfare Center Crane Division has inaugurated the Navy's first in-house Metal Additive Manufacturing Repair Center. This facility enhances repair capabilities, reduces contractor reliance, and aims to improve fleet readiness through advanced additive manufacturing processes.

Government contractors encounter significant hurdles in applying 3D printing for critical applications due to quality standards. Focusing on non-structural components through existing contract vehicles could open new avenues for small businesses, particularly Service-Disabled Veteran-Owned Small Businesses (SDVOSBs).

Senator John Cornyn has introduced legislation aimed at creating a pilot program for 3D-printed materials in defense. This initiative seeks to enhance safety and modernize procurement processes, presenting fresh opportunities for contractors in advanced manufacturing.

Lockheed Martin, in tandem with Divergent Technologies, has developed the Replicator drone prototype via advanced 3D printing. This $25 million investment underscores a major shift towards innovative and agile manufacturing processes, which may redefine procurement strategies in defense acquisitions.

The U.S. Army has executed Project Flytrap in Lithuania, testing over 20 counter-drone technologies with NATO allies. The focus on advanced **counter-unmanned aerial systems** and **additive manufacturing** technologies reflects a significant pivot in procurement priorities, shaping future defense strategies and procurement opportunities in the military technology landscape.

The U.S. Air Force has awarded AEVEX Corp. an $18.5 million contract for the production of Group 3 unmanned aircraft systems designed for One Way Attack missions. This shifts focus toward integrating **additive manufacturing** technologies, enhancing procurement strategies for drone capabilities and supply chain collaboration.

The US Navy has received its first portable ARCEMY system from AML3D, enhancing its manufacturing capabilities. This A$1.2 million deal may lead to a larger supply relationship through 2030, indicating a shift towards advanced, on-site production capabilities in defense procurement.