Introduction
Additive Manufacturing is a form of technology that has been in high demand in the manufacturing industry in the recent past due to its ability to generate effective and efficient products. This technology is also known as 3D printing. The technology has drawn the attention of the manufacturing and commercial fields and gained entry into the military and defence sectors, especially in the United States Department of Defense (Direct Industry, 2023). It is highly applicable in the military for several purposes, including logistical purposes, manufacture of light and heavy gauge military-grade weapons, transport sector, mapping and generation of accurate coordinates, and collecting vital military intelligence and data that facilitate military actions. According to Kobryn et al. (2006), SD printing has been in the military spaces since the early 1990s, when the technology was first developed to curb emerging and advanced military threats. The technology remained in testing and pilot plants in the entire 90s until the late 2000s when the military fully adopted the use of 3D technology to conduct several military operations and activities, thus widely boosting the applicability of this technology across all sectors, not the military alone.
The logistical application of additive manufacturing technology in the United States military in the 2000s led to a total breakthrough in the force. Through the use of 3D printing technology, military operations greatly improved since there were significant improvements in the reduction of lead times, improvement in the supply chain sector as well as the flexibility of the force in fighting in adverse climatic conditions due to the benefits associated with the 3D printing technology (DirectIndustry, 2023). In addition, the military’s application of 3D printing technology in the logistics department is perhaps one of its most significant contributions to the industry. The force obtained an adequate supply of spare parts, fighting materials, a better understanding of terrains and the development of better software that enabled them access closer to their enemy zones.
For instance, the United States Army were able to access and establish military camps and fighting zones in Afghanistan and Iraq since the technology facilitated their operation through the production of better equipment, spare parts and other essential military requirements that were able to be produced easily in the army labs, unlike in the past time where spare parts and other essential equipment supply was mainly relied on to be supplied from the United States bases in the country (Businesswire, 2021). Additionally, an example of the United States of America’s Air Force, which has produced state-of-the-art fighting equipment such as the modern deadly fighter jets that, include the F-22 and the F-35 that have resulted in great success in the warzones participated by the United States military (Cunningham et al., 2015). Therefore, the use of addictive technology has led to tremendous success in the Air Force because it has been able to reduce the cost and time required to produce spare parts for these aircraft, thus ensuring they are always combat-ready.
Another critical military body that has greatly adopted the use of additive manufacturing is the United States Navy. The technology has facilitated the naval group built modern war vessels that include naval ship parts and other critical components (Gupta et al., 2012). Through 3D technology, the United States Navy has produced needed military equipment that has improved the supply of war equipment and spare parts for broken-down machines. The technology has further improved the operations of the Navy by reducing the cost of producing these parts and enhancing the quality and accuracy of the parts produced (Cunningham et al., 2015). The technology has further improved the marine ability of the Navy to gather needed military information and intelligence as well as collect data. Through the Navy laboratories, 3D printing technology has greatly resulted in the production of complex structures and components for testing purposes, which has played a key role in the success of the Navy in various operations (Cunningham et al., 2015). For instance, 3D printing technology has yielded a critical fighting vessel known as the Optionally Manned Fighting Vehicle that has great efficiency and accuracy, thus improving military operations.
In summary, the use of 3D technology has been a breakthrough in the all-around sector, with key improvements brought to the military and defence sectors. It has led to the development of modern fighting vessels and spare parts that have greatly improved the quality of service delivery and military operations in various parts of the world, including Iraq and Afghanistan. Technology has also positively impacted the manufacturing and commercial sector by improving the quality of services and products being generated by such fields of sectors. It has also improved the research sector by facilitating the research methods, data collection equipment as well as data handling techniques. Therefore, the technology has promoted the reduction of costs, increasing flexibility in all sectors, and improving supply chain management through better spare part supply.
Overview of Selected Topic
Additive Manufacturing is a manufacturing process that involves the layer-by-layer construction of a product using digital design data. 3D technology has brought a positive revolution in various industries and sectors by enabling the creation of complex and customized parts, reducing production time and costs, and improving efficiency (Cunningham et al., 2015). A key example of how the system has contributed to positive change is the United States military and government that have embraced 3D technology, recognizing its potential to enhance their operations and capabilities in data collection, vehicle manufacture, plane customization, and establishing military bases fighting their enemies. This section highlights and focuses on the process, structure, property, and performance of Additive Manufacturing parts in the United States military and government, specifically on aerospace alloys used in aircraft structures.
3D Printing Technology Process
The 3D printing technology processes use various materials, such as polymers, metals, ceramics, and composites, to construct parts. The addictive manufacturing process starts with printing various models in 3D that will be used for fabrication and design purposes to generate the intended end product. According to Cunningham et al. (2015), the process employs the use of computer-aided design software that converts the 3D models into formats that are compatible with the Additive Manufacturing machine for further processing. The machine then uses a layer-by-layer approach followed by a series of manufacturing processes and practices that include melting, sintering, and, finally, curing the material. The end product is achieved through a machine-follow instructions program that ensures all the commands fed into the machine get implemented to generate the final end product in 3D.
Structure of Additive Manufacturing Parts
Addictive manufacturing parts have unique structures that differ from parts created using traditional manufacturing methods. The structure of Additive Manufacturing parts is determined by the layer-by-layer approach, which creates a grain structure that is perpendicular to the build direction. The grains’ orientation affects the part’s mechanical properties, such as strength and ductility (Direct Industry, 2023). Additionally, Additive Manufacturing parts may have residual stresses due to the heating and cooling cycles during manufacturing. The residual stresses can affect the performance of the part. Hence it is critical to consider this during the design and manufacturing process.
The 3D parts offer several benefits, such as reduced lead times, increased design flexibility, and improved customization. Furthermore, the unique structures of Additive Manufacturing parts can provide enhanced performance characteristics that are particularly relevant in military applications (Gupta et al., 2012). Additive Manufacturing parts can be produced on demand, reducing the need for large spare parts inventories and decreasing the logistics burden. This can result in significant cost savings and increased readiness.
Another benefit of Additive Manufacturing parts is their flexibility in design. Traditional manufacturing methods often require complex tooling and machining processes to produce complex geometries. With Additive Manufacturing, complex parts can be designed and produced without requiring specialized tooling, reducing costs and lead times. This is particularly relevant in the military, where unique and customized parts are often required for specific missions or equipment (Shaikhnag et al., 2021). The unique structures of Additive Manufacturing parts also offer enhanced performance characteristics that are particularly relevant in military applications. Furthermore, Additive Manufacturing parts can be produced with internal channels or voids, which can be used to reduce weight or improve cooling.
However, the unique structures of Additive Manufacturing parts also present challenges regarding quality control and testing. The orientation of the grains and residual stresses can affect the part’s mechanical properties, making it important to carefully consider the design and manufacturing process. Additionally, Additive Manufacturing parts may require specialized testing procedures to meet the required performance specifications. Despite these challenges, the military increasingly turns to Additive Manufacturing to produce parts and components (Cunningham et al., 2015. This is particularly relevant in remote or austere environments where traditional manufacturing methods may not be feasible (Kingsbury, 2019). Additive Manufacturing can produce parts on-site, reducing the logistics burden and increasing operational readiness.
Therefore, additive manufacturing parts have unique structures that differ from parts produced using traditional manufacturing methods. These structures offer several benefits, such as reduced lead times, increased design flexibility, and enhanced performance characteristics. However, the unique structures of Additive Manufacturing parts also present challenges in terms of quality control and testing (Businesswwire, 2021). Nonetheless, Additive Manufacturing is increasingly being used in the military sector to produce parts and components, particularly in remote or austere environments where traditional manufacturing methods may not be feasible.
Property of Addictive Manufacturing Parts
Additive Manufacturing parts have unique properties that differ from those created using traditional manufacturing methods. The mechanical properties of the 3D printing technology parts include strength, ductility, and toughness, which are all dependent on several factors. Some of the factors that determine the properties of this 3D printing technology model include; the materials used, processing parameters, and the geometric elements of the target part (Cunningham et al., 2015). The properties of the 3D technology parts can be tailored to meet specific requirements by adjusting the process parameters, such as the temperature, laser power, and scan speed (Cunningham et al., 2015). Additive Manufacturing parts can also have a higher density than traditionally manufactured parts, resulting in improved mechanical properties.
Performance of Additive Manufacturing Parts
Additive Manufacturing technology, commonly called 3D printing, has gained significant attention and popularity in various industries in recent years. The United States military and government have also shown interest in the potential benefits of Additive Manufacturing technology (Kingsbury, 2019). Furthermore, Additive Manufacturing has significantly reduced the production time of these parts, allowing the aerospace industry to meet tight production deadlines. Additive Manufacturing technology has also shown its potential in the medical industry (Gradl et al., 2022). Customized implants and prosthetics can be created with 3D printing technology; thus, it gives the patient an opportunity to have preferences in medical appeal (Mekinews, 2022). The application of this technology in the medical sector has facilitated the production of intricate structures that would have been challenging to produce with traditional manufacturing methods (Kobryn et al., 2006). Additionally, the speed and flexibility of the 3D printing technology have also enabled medical professionals to quickly produce the necessary parts and tools, improving patient care and the general quality of service in the medical sector.
Military medical facilities have adopted this technology to dress wounded soldiers and preserve the bodies of fallen soldiers in war zones. The military has been exploring the use of Additive Manufacturing technology to create spare parts and repair damaged parts in the field (Mekinews, 2022). With the ability to produce parts on demand and in remote locations, Additive Manufacturing technology can reduce traditional part production’s logistics and supply chain challenges. Additive Manufacturing technology also allows for the customization of parts to meet specific military needs, making it a promising solution for military applications.
Additive Manufacturing technology has shown promising performance in various United States military and government applications. More advanced aerospace vessels have emerged due to the application of additive manufacturing technology. These vessels are more effective, efficient, and accurate (Gupta et al., 2012). As technology evolves, Additive Manufacturing is expected to become more widespread and offer even more benefits to various industries.
Aerospace Alloys for Aircraft
Aeroplanes and other space vessels need specific materials of manufacture that enhance safety and easy mobility in space. Therefore, several materials are blended together to generate one final product that is able to fit the manufacture of these space vessels (Kobryn et al., 2006). These materials are called aerospace alloys that are made of titanium, aluminium, and nickel-based superalloys. They have absolutely high properties that favour their use and stay in the space. Such properties are a high strength-to-weight ratio, good fatigue resistance, and excellent corrosion resistance (Gradl et al., 2022). Researchers have studied the properties and performance of Additive Manufacturing parts made of aerospace alloys and compared them to traditionally manufactured parts.
Conclusion
In summary, additive manufacturing, which is also known as 3D printing manufacturing technology, has resulted in several positive impacts in various fields and sectors. The commercial sector, medical field, military, and the manufacturing or fabrication sector has employed the concepts of technology and utilized them to improve their quality of service delivery. For instance, the United States of America’s military sector is the major beneficiary of this technology since it has been widely employed by the US Army, US Navy and the US air force (Kobryn et al., 2006). Through addictive manufacturing technology, these security teams have successfully conducted military operations in several parts of the world that include Iran, Afghanistan, Somalia and Libya. Therefore, this technology has provided significant benefits across the sector board in terms of reducing the costs of operation, increasing the efficiency of service delivery and conducting operations, and decreasing lead time for manufacturing and maintenance of equipment. The military has embraced the use of 3D printing technology for rapid prototyping and end-use production. These practices have resulted in a general improvement in military operations, such as combat readiness, reduced downtime, and increased mission effectiveness.
Additive manufacturing has also revolutionized the vehicle and plane manufacturing industry. Although the United States military has widely adopted this technology, other sectors have also adopted it, and enhanced large-scale productivity has been achieved. Vehicles, ships, and planes have been manufactured through the concepts of 3D printing technology that withstand adverse climatic conditions, thus indicating how the addictive manufacturing technology has contributed to spearheading the manufacturing of all-round and effective machinery. It has also become instrumental in the production of lightweight and complex geometries that would have been challenging to produce through alternative manufacturing approaches.
References
Businesswire (2021). Primus Aerospace Adopts VELO3D’s Titanium AM System to Unlock the Future of Design for the Aerospace and Defense Industry. https://www.businesswire.com/news/home/20210316005206/en/Primus-Aerospace-Adopts-VELO3D%E2%80%99s-Titanium-AM-System-to-Unlock-the-Future-of-Design-for-the-Aerospace-and-Defense-Industry
Cunningham, V., Schrader, C. A., & Young, J. (2015). Navy additive manufacturing: adding parts, subtracting steps. NAVAL POSTGRADUATE SCHOOL MONTEREY CA. https://apps.dtic.mil/sti/pdfs/ADA632470.pdf
Direct Industry (2023). Spinal Implant Manufacturing Using EP-M250 Metal 3D Printer by Eplus3D Tech Co., Ltd. Direct Industry. Retrieved 17 April 2023, from https://trends.directindustry.com/eplus3d/project-235666-1133240.html
Gradl, P., Tinker, D. C., Park, A., Mireles, O. R., Garcia, M., Wilkerson, R., & Mckinney, C. (2022). Robust metal additive manufacturing process selection and development for aerospace components. Journal of Materials Engineering and Performance, 31(8), 6013-6044. https://link.springer.com/article/10.1007/s11665-022-06850-0
Gupta, N., Weber, C., & Newsome, S. (2012). Additive manufacturing: status and opportunities. Science and Policy Institute Technology, Washington. https://www.researchgate.net/profile/Justin-Scott-4/publication/312153354_Additive_Manufacturing_Status_and_Opportunities/links/59e786db458515c3630f917b/Additive-Manufacturing-Status-and-Opportunities.pdf
Kingsbury (2019). How Rolls Royce is embracing additive manufacturing in its aircraft engines | Kingsbury. Retrieved 17 April 2023, from https://kingsburyuk.com/how-rolls-royce-is-embracing-additive-manufacturing-in-its-aircraft-engines/#:~:text=What%20technology%20does%20Rolls%20Royce,beam%20melting%20technology%20(EBM)
Kobryn, P. A., Ontko, N. R., Perkins, L. P., & Tiley, J. S. (2006). Additive manufacturing of aerospace alloys for aircraft structures. Air Force Research Lab Wright-Patterson AFB OH Materials and Manufacturing Directorate. https://apps.dtic.mil/sti/pdfs/ADA521726.pdf
Mekinews (2022). Stratasys, record deal with US Airforce: 3D printers for aircraft – Trade used Machines. Retrieved 17 April 2023, from https://www.trade-used-machines.com/stratasys-record-deal-with-us-airforce-3d-printers-for-aircraft/
Shaikhnag, A., Shaikhnag, A., Shaikhnag, A., Shaikhnag, A., Hanaphy, P., & Hanaphy, P. et al. (2021). Lockheed Martin selects Sigma Labs PrintRite3D technology to support space division – 3D Printing Industry. Retrieved 17 April 2023, from https://3dprintingindustry.com/news/lockheed-martin-selects-sigma-labs-printrite3d-technology-to-support-space-division-186397/
write