Defending innovation: 3D printing's role in modern warfare

3D printing, also known as additive manufacturing, is a method used to create physical objects from a digital design. The 3D-printed item is produced through this additive process, in which an object is made by adding one layer of material on top of another until the final shape is formed. Each layer can be thought of as a thin, sliced section of the object.

However, there is one exception, known as volumetric 3D printing, through which entire structures can be created all at once, instead of building them a layer at a time. However, volumetric technology is still mostly in the research stage at this time.

The 3D printing process is the opposite of subtractive manufacturing, in which, instead of carving out a particular shape from a solid block of material, as done with a milling machine, an object is built by adding layers of material. 3D printing allows the creation of intricate shapes using less material compared to traditional manufacturing methods.

3D printing is widely used across industries, from creating such consumer products as eyewear and furniture to industrial tools, prototypes and functional parts. It is also revolutionising fields, such as dentistry and prosthetics by enabling efficient production of custom items.

How does 3D printing function?

The process begins with a 3D model. You can either design it yourself or download one from a 3D model library. Since the late-1970s, companies have been using 3D printers in their design process to make prototypes. This practice is known as rapid prototyping. It is fast and cost-effective. You can take an idea, turn it into a 3D model and have a physical prototype in hand within days, not weeks.

Adjustments are simpler and cheaper, without requiring expensive molds or equipment. Besides rapid prototyping, 3D printing is used for rapid manufacturing. This is a modern manufacturing method where companies use 3D printers to produce small batches or custom items in limited quantities quickly and efficiently.

3D printing in aerospace & defence

The aerospace and defence industry has been using 3D printing technology for several years. According to Market Research Future, the 3D printing market in this sector is projected to grow to $5.58 billion by 2026. This growth has been so impactful that 70% of industry professionals believe it has completely changed how the sector thinks and functions.

It is not surprising that almost 75% of industry experts reported using 3D printing for prototyping. Additionally, 44% apply it for repair and maintenance, 43% for research and development and nearly 40% for producing parts. Around 33% use 3D printing to create jigs, fixtures and tooling, or for temporary production.

Also read: Indian Army’s ‘HIM-DRONE-A-THON 2’ to test made-in-India drones at high-altitudes

A few years ago, simply using 3D printing in defence and aerospace manufacturing provided a significant competitive advantage. Companies quietly experimented with materials and techniques to stay ahead of their competitors by improving performance, making things lighter, or reducing the size of what they carry. Today, the focus on materials is expanding beyond plastics to include metals, opening up new possibilities.

As 3D-printed metals become more widely adopted, we can expect a significant increase in their use across the defence, aerospace and space industries. Nearly 90% of industry professionals predict their use of 3D printing will at least double in the coming years.

Advancing aerospace and defence

While 3D printing is still in its early stages in some areas, it is already being used for parts that carry a higher level of risk. Today, companies in the industry are growing confident and now moving beyond using 3D printing for simple plastic parts. They are starting to apply it to more complex areas, such as secondary structures—not the main framework—and important systems in defence and aerospace projects.

There are many advantages of using 3D-printed parts in the aerospace and defence industries.

1. Streamlining parts with Bill of Materials (BOM) simplification

Additive manufacturing offers companies more design flexibility by encouraging them to think beyond individual components. For instance, a cooling system fan that usually requires up to 78 complex parts can be simplified into a single piece using 3D printing. This not only makes assembly faster and reduces failure points, but also cuts down on waste compared to traditional manufacturing methods.

While simplification is a major advantage, 3D printing also enables the production of complex designs that traditional methods, such as injection moulding, cannot achieve. This gives engineers the freedom to create parts optimised for better performance. From a manufacturing standpoint, it allows for smarter designs, reduces tooling costs and improves the durability and lifespan of parts.

2. Facilitate on-demand, localised manufacturing and production

Supply chain innovations in the aerospace and defence industry that allow faster production are an important factor in reducing time-to-market, essential for success in any industry. One of the best ways of speeding up production is by using on-demand manufacturing. Regardless of the certifications or qualifications needed, this manufacturing process can use standard equipment without needing specific tools for each part, allowing specialised components to be made anywhere in the world.

Industry experts believe that additive manufacturing has helped them speed up production. Since the design files are digital, they can easily be customised for different needs. With no need to change tools or moulds, the process mainly focuses on updating designs, making it more efficient.

Mass customisation does not always mean producing just one item. With 3D printing, it can mean reducing a production batch from 10,000 units using traditional methods to just 100 units, making it more efficient and tailored to specific needs.

3. Lower supply chain expenses with localised additive manufacturing

Reducing a component from 78 separate parts to just one has a big impact on the entire supply chain. Fewer parts mean a simpler, more efficient supply chain, leading to more reliable and consistent production. For instance, the industry no longer requires a foundry to create a metal part that is then sent to a machine shop for finishing before being shipped to its destination. The aim is to achieve vertical integration, where the entire process—from design to production—happens in one facility, without needing outside suppliers. This includes producing such materials as certified powders and using 3D printing to make parts.

By allowing machine shops to operate independently with these materials, local production can be done, cutting down on shipping costs and long wait times associated with traditional manufacturing, making everything faster and more efficient.

3D printing for missiles & rockets

1. Boosting India’s missile production: Missiles, such as the Very Short-Range Air Defence Systems (VShoRADS) and Man-Portable Anti-Tank Guided Missiles (MPATGM) are vital for battlefield defence. These missiles rely on launch motors and, in the case of VShoRADS, sustain motors (which help maintain the missile’s speed after launch). Traditionally, these motors are made from special steel alloys using extrusion methods.

Even though production is going on, the current capacity may fall significantly short of wartime demands. At full capacity, roughly 2,000 units could be produced per year, a number which could be exhausted in only a couple of months of heavy fighting.

The DRDO and its production partners are looking at 3D printing as a way to solve this issue. The technology can create complex parts, such as rocket motor casings, much faster than traditional methods. While it may take around a month to produce a motor using extruders, 3D printing can achieve it in only 3-4 days.

3D printing can greatly speed up the production of essential missile parts, helping to quickly restock supplies during the war. This technology can increase overall production, allowing for more missiles to be made in less time. Flexibility in operations also helps in creating new and innovative missile designs that have complex shapes, thus greatly enhancing performance.

Although 3D printing holds great promise for India’s missile production, more R&D is required. It is essential to refine the printing methods for specific materials and ensure that the printed components meet high standards of quality and reliability.

2. Rapid defence construction: India’s Military Engineering Services (MES) has used 3D rapid construction technology from private companies to build two houses at the South-Western Air Command in Gandhinagar and Jaisalmer. However, the military is now also building bunkers and vehicle parking facilities in border areas where traditional construction methods are difficult because of harsh weather conditions and labour constraints.

3. ISRO’s success with 3D-printed rocket engine: On May 9 this year, the Indian Space Research Organisation (ISRO) successfully tested a liquid rocket engine created using 3D printing. ISRO redesigned the PS4 engine, used in the fourth stage of the Polar Satellite Launch Vehicle (PSLV), for 3D printing. This technology reduced the number of engine parts from 14 to just one, eliminating 19 weld joints and saving 97% of raw material. It also cut production time by 60%.

Aerospace, defence, MRO unified

• In 2015, Russia began using industrial 3D printers to create prototype components and master models for its third-generation T-14 main battle tank (MBT), based on the ‘Armata’ universal chassis system. This development was disclosed by the head of the Rapid Prototyping Lab at Electromashina, a division of Uralvagonzavod (UVZ), the world’s largest main battle tank manufacturer. Alexander Loktev, Managing Director of ETC Tecnopolice in Moscow, which supplies essential tooling and quality equipment to various sectors in Russia, provided this information.
• In January 2020, Hindustan Aeronautics Limited (HAL) and Wipro 3D signed an MoU to collaborate on designing, developing, manufacturing and repairing aerospace components using metal 3D printing. The partnership aims to explore new materials for metal additive manufacturing, with a focus on creating and certifying aerospace parts, including maintenance, repair and overhaul (MRO) components, ensuring their reliability through rigorous testing.
• 3D printing could greatly enhance the production of parts for such older equipment as fighter jets and transport aircraft, besides producing advanced materials, such as titanium and graphene and hybrid components, which is expected soon. In mid-2022 the Indian Army used 3D printing to prototype a 9mm pistol, with such metal-printed parts as the trigger, featuring an aircraft-grade aluminium top receiver and a carbon fibre lower receiver.

(The author of this article is a Defence, Aerospace & Political Analyst based in Bengaluru. He is also Director of ADD Engineering Components, India, Pvt. Ltd, a subsidiary of ADD Engineering GmbH, Germany. You can reach him at: [email protected])