Additive manufacturing addresses critical technical and financial challenges in defence applications. Offering flexibility, speed, and responsiveness from prototype to end-use part, governments worldwide increasingly encourage the integration of this technology into the military sector.
From a technical perspective, additive manufacturing delivers many benefits in terms of reliability, performance, and durability for equipment operating under extreme conditions. Financially, it supports cost control in development, maintenance, and modernization, all within an accelerated innovation cycle.
Whether for low-volume production, prototyping, or specialized tooling, 3D printing provides decisive advantages. Explore the role of 3D printing in manufacturing thermoplastic components for the defence sector.
- Low-Volume Production for Defence
- Prototype Development for the Defence Industry
- Specialized Tooling for Defence Applications
- Defence in Action: Case Studies
- Solaxis: A Trusted Partner in Defence Additive Manufacturing
Low-Volume Production for Defence
Thanks to its ability to quickly produce parts without costly moulds or tooling, 3D printing efficiently meets the needs of low-volume technical production.
This is particularly relevant in the defence industry, where production often involves limited quantities, such as for fighter jets, armoured vehicles, drones, or specialized communication systems.
Unlike consumer industries, where mass production is the standard, defence requires agile, customized, and rapidly adaptable solutions.
High-performance polymers such as PEKK, ULTEM™ (PEI), and carbon-fiber-reinforced nylons provide mechanical and thermal properties that meet the sector’s stringent demands (resistance to impact, heat, chemical corrosion, and UV exposure). In this context, thermoplastic 3D printing proves to be a highly relevant solution.
Components for Military Ground Vehicles
Sensor mounts, weapon supports, custom brackets, panels, protective covers, and more.
Materials: Reinforced polymers designed to withstand severe mechanical stress.
Aerospace Parts (Aircraft, Helicopters, Drones)
- Fairings, electronic housings, access panels, ventilation ducts, protective covers, camera mounts.
- Lightweight yet durable, these components help reduce overall weight while maintaining structural strength.
Components for Space and Defence Satellites
- Protective enclosures, thermal covers, vents, housings, reflectors, deployable antennas, lightweight internal structures.
- 3D printing enables advanced design freedom and high-level functional integration.
MRO (Maintenance, Repair & Operations) Parts
- Fast replacement of worn or obsolete components, often unavailable through traditional supply chains.
- Minimizes downtime for critical defence equipment.
Electronic, Optical & Radar Housings
- Sensor enclosures, radar housings, optical supports, components with integrated EMI shielding.
- Enables rapid production of small batches with multifunctional integration (structure and protection).
Custom Soldier Equipment
- Tailored body armour, custom splints, exoskeleton adapters, and shin guards moulded to individual body shapes.
- Reduces carried load and enhances comfort in the field.
- Reduces carried load and enhances comfort in the field.
Prototype Development for the Defence Industry
In the defence sector, where technological innovation is a strategic driver, the ability to quickly prototype functional parts represents a major competitive advantage. Thermoplastic 3D printing stands out as an essential tool to accelerate development cycles, reduce design costs, and validate solutions under real-world conditions before full-scale production.
With engineering-grade materials compatible with additive manufacturing, prototypes can be produced with properties close to the final parts. This allows not only validation of shapes and geometries, but also testing of mechanical and functional performance.
Prototyping of Parts for Land or Armoured Vehicles
- Cabin interiors, body components, protective or fastening parts.
- Ergonomics, fit, and integration can be evaluated before moving into serial production.
- Ergonomics, fit, and integration can be evaluated before moving into serial production.
Demonstration Models
- Production of parts for marketing and presentation purposes (trade shows, events, end-user demonstrations, functional mock-ups).
- Faithful reproduction of complex geometries at a reduced cost.
- Faithful reproduction of complex geometries at a reduced cost.
Prototyping of Customized Equipment for Military Personnel
- Rehabilitation splints, demonstration helmets, exoskeleton interfaces, ergonomic protective gear.
- Testing adaptability to specific body types and field constraints.
- Testing adaptability to specific body types and field constraints.
Temporary or Functional Replacement Parts
- Parts used to validate machining programs or test CMM (Coordinate Measuring Machine) inspection programs before series launch.
- Substitution of delayed components to complete complex assemblies.
- Substitution of delayed components to complete complex assemblies.
Prototyping for Tactical Drones
- Miniature wings, sensor mounts, camera supports, internal structures.
- Multiple iterations can be produced rapidly to optimize aerodynamics and payload integration.
- Multiple iterations can be produced rapidly to optimize aerodynamics and payload integration.
Prototyping of Aeronautical Components: Form and Function Testing
- Ventilation ducts for onboard HVAC systems, flight instrument supports, cabin trim panels, airline logos.
- Significantly faster development time compared to traditional manufacturing methods.
- Significantly faster development time compared to traditional manufacturing methods.
Specialized Tooling for Defence Applications
In a sector where operational responsiveness, cost efficiency, and production versatility are critical, thermoplastic 3D printing offers a highly suitable solution for manufacturing specialized tooling. By reducing lead times and costs compared to traditional processes, defence manufacturers gain greater autonomy and agility.
Additive manufacturing enables the production of custom tooling which can be quickly modified and perfectly adapted to complex geometries or the specific constraints of military programs. Using high-performance polymers resistant to mechanical, thermal, or chemical stress, 3D printing has become a mature technology for producing robust, functional tooling designed for demanding production and maintenance environments. Here are some examples.
MRO Tooling (Maintenance, Repair & Operations)
- Inspection jigs, intervention supports, and specialized tools for military equipment maintenance.
- Reduced downtime and improved logistics.
Composite Part Manufacturing Tooling
- Lay-up moulds, inserts, positioning jigs.
- Adapted to complex shapes and composite manufacturing thermal cycles, with heat-resistant materials (e.g., ULTEM).
Assembly Jigs and Fixtures
- Custom seats to position or hold components during the assembly of onboard systems (aircraft, drones, armoured vehicles).
- Possible integration of features: guides, markers, reference surfaces.
Thermoforming or Overmoulding Moulds
- Design of short- or medium-run moulds, enabling process validation or the production of a limited number of parts at lower cost.
- Excellent alternative to aluminum moulds for low-volume series.
Cutting and Drilling Jigs
- Lightweight, customized, and rapidly deployable in workshops or operational environments.
- Usable directly in the field for quick maintenance operations.
Custom Supports and Hinges
- Handling, fastening, or integration aids for sensitive systems.
- Ergonomic design possible with user-specific customization.
- Ergonomic design possible with user-specific customization.
Defence in Action: Case Studies
Amid rising geopolitical tensions, the global arms race has driven increased military investments, particularly in remotely operated systems such as reconnaissance vehicles and drones. Major powers like the United States, China, Russia, and the European Union are seeking to strengthen their strategic superiority.
Marshall Aerospace cuts aerospace duct weight by 63%
Based in the UK, Marshall Aerospace leverages 3D printing to produce prototypes and aerospace components using high-performance thermoplastics like ASA, Nylon 12, and ULTEM 9085.
For example, a duct adapter for ground support equipment printed in Nylon 12 reduced weight by 63% compared to a machined aluminum part, generating substantial cost savings.
Additionally, Marshall now produces multiple flight-certified aircraft ducts, thanks to the precision, repeatability, and reliability of 3D printing.
Additive manufacturing is also applied to low-volume tooling (jigs, fixtures, and custom tools) produced in under 24 hours with consistent repeatability.
Source: Stratasys
Lockheed Martin saves $45M on F-35 flight simulators
By integrating 3D-printed components (housings, supports, simulation elements), Lockheed Martin reduced the cost per full mission simulator (FMS) for the F‑35 by approximately $3 million.
The initial low-rate production batch (LRIP 11) of 15 simulators resulted in a total savings of roughly $45 million for the F‑35 program.
Source: 3D Printing Industry
Solaxis: A Trusted Partner in Defence Additive Manufacturing
Solaxis specializes in industrial 3D printing of thermoplastic parts, with a strong focus on the defence sector. The company stands out for its technical expertise, state-of-the-art printer fleet (FDM, FFF, SLS), and ability to produce large-format components. This flexibility enables efficient responses to the productivity, quality, and timeline demands unique to the military sector. We also offer a wide range of materials, including FST-certified thermoplastics that meet the strict safety and performance standards required for defence applications.
As a strategic partner for defence projects, Solaxis delivers solutions tailored to the sector’s complex requirements, combining innovation, precision, and traceability.
If you work in the defence sector and are looking to innovate, validate a concept, or produce low-volume parts, our team of experts is ready to guide you.