Additive manufacturing offers the defence industry a fast and flexible way to produce parts, making it a highly valuable solution for stakeholders. This technology allows for the efficient design and fabrication of complex components that meet high mechanical requirements, including those made from thermoplastic materials. Below are some key benefits that are particularly relevant to the defence industry.
With a geopolitical context that is constantly evolving, military responsiveness has become a critical factor in supporting the preparation and deployment of armed forces.
Time is a vital resource in the defence sector. Whether it’s designing parts on demand, low-volume production, prototyping, or tooling, speed of delivery is crucial. This is especially true in a highly competitive global environment where massive investments are being made to develop military-grade components.
The global arms race is accelerating, fuelling intense technological competition. Having effective defence capabilities is a strategic necessity for major global powers. This includes not only developing ever more advanced equipment, but also ensuring the maintenance and availability of assets already in service.
Rearmament occurring in strategic regions such as the Arctic and the European Union highlights the urgent need for fast, efficient solutions. Additive manufacturing stands out as an optimal response. It offers unprecedented flexibility and agility, enabling rapid implementation and customized production. Thanks to 3D printing, multiple design iterations can be completed without major constraints, accelerating both development and sustainment of military equipment.
The defence sector faces constant and complex challenges. Needs evolve rapidly, and additive manufacturing—with its ease of implementation—enables the design of parts with highly specific and complex physical or geometric properties. These parts can be tested and validated quickly for a variety of applications, whether as end-use parts, functional prototypes or proofs of concept.
The table below provides a general, informative only comparison of production lead times for thermoplastic components used in the defence sector, comparing traditional methods (machining or moulding) with 3D printing (FDM, SLS). It highlights the estimated time savings offered by additive manufacturing for various types of technical parts.
|
Component Type (Defence) |
Traditional Method (Machining or Moulding) |
3D Printing (FDM, SLS) |
Estimated Time Savings |
|
Lightweight drone fairing / sensor housing |
2–4 weeks (plastic machining or thermoforming) |
2-5 days |
~80–85% |
|
Custom radio / electronics enclosure |
2–3 weeks (plastic machining or silicone moulding) |
2-4 days |
~80–85% |
|
Internal ducts (airflow or HVAC) |
2–3 weeks (machining or composite manufacturing) |
2-5 days (depending on size) |
~75–85% |
|
Functional cockpit panel mock-up |
4–6 weeks (manual assembly + paint) |
3-10 days (multipart printed and assembled) |
~75-90% |
In addition to meeting productivity demands, additive manufacturing simplifies the military supply chain. Without the need for tooling, on-demand production significantly reduces lead times.
Industrial-grade additive manufacturing enables optimized stock management by turning physical inventory into a digital library of printable parts.
By consolidating multiple components into a single part, it also significantly reduces the number of suppliers and tooling requirements.
Compared to traditional manufacturing methods in the defence industry, additive manufacturing can reduce overall project costs depending on production volumes. By eliminating the need for specialized tooling and associated costs, it provides a more flexible alternative. Additionally, part consolidation reduces production steps, such as assembly.
Using 3D printing, Sheppard Air Force Base designed training simulators (UAVs, avionics systems, medical, telecom) in very low volumes at a fraction of the time and cost of traditional manufacturing technologies.
Industrial 3D printing enables:
- Over 60% reduction in lead times, especially during prototyping and tooling phases.
- Up to 80% reduction in weight, improving ergonomics and productivity.
- Cost savings in labour, logistics, inventory, and handling.
Thermoplastic 3D printing contributes to reducing the environmental footprint of the defence sector by optimizing material usage and limiting waste.
This technology significantly reduces material waste by adding material only where needed, unlike traditional subtractive methods, which remove excess material.
Other environmental benefits include:
Are you in the defence sector and looking to innovate, validate a concept, or produce low-volume parts? Our team of experts will be happy to guide you. Contact us!