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.
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.
Sensor mounts, weapon supports, custom brackets, panels, protective covers, and more.
Materials: Reinforced polymers designed to withstand severe mechanical stress.
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.
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.
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.
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
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 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.