3D printing is no longer a futuristic promise, but rather a strategic tool in the military field.
In recent years, the 3D printing has profoundly transformed the aerospace industryand its impact on the military is becoming increasingly evident. Beyond prototyping or the manufacture of lightweight parts, the armed forces of countries such as the United States, the United Kingdom, Germany and Israel are incorporating this technology into their strategic operations. Why? Because it allows manufacture essential parts in record time, reduce logistical dependency and adapt quickly to extreme conditions.
At Additium 3D we work with solutions from aerospace 3D printing focused on efficiency, resilience and adaptation to demanding environments. But what exactly is happening internationally?
Military applications of 3D printing in the armed forces of different countries
United States: 3D printing on the battlefield
The US military has developed mobile laboratories equipped with 3D printers that are deployed alongside the troops. This allows them to manufacture spare parts and components instantly, without waiting for them to arrive from distant bases.
In addition, the Pentagon has approved use of 3D printed parts for the maintenance of such complex systems as Black Hawk helicopters and Abrams tanks. This decision not only reduces costs, but also minimises operational downtime.
In 2019, the Marine Corps printed a 46 m² barracks in only 40 hoursThe 3D printing industry, a clear example of how 3D printing is also revolutionizing the military construction in remote areas.
And we're not just talking about operability: the Department of Veterans Affairs (VA) already makes 3D customised prosthesesThe new system provides veterans with solutions tailored to their real needs.
UK: drones and logistics within 24 hours
The British Army has developed military drones that are 3D printed and assembled in less than 24 hours, used in reconnaissance missions. This speed provides a significant tactical advantage in critical operations.
During military exercises, they have also tested printing parts in situ to replace failed components, a strategy that has been used in the past. reduces logistical vulnerability and improves autonomy in the field.
Germany: decentralised production with metal
The Bundeswehr has opted for a decentralised production which allows parts to be printed directly on the deployed bases. Thanks to the collaboration with companies such as EOS, the following are being developed high-strength metal components applicable to defensive systems and armaments.
Israel: agility and innovation in military bases
The Israel Defence Forces (IDF) have 3D printers in their own baseswhich allows them to produce tools, adapters and mechanical parts immediately. Even in emergency medical situations, they have manufactured critical components for medical equipment.
France: Rapid prototyping and logistical support
The French navy uses 3D printing to design new weapons and maintenance tools in less time. In operations in Africa, printers have been used to reduce reliance on shipments from Europe, improving logistics autonomy.
NATO and other countries: Integration and global expansion
NATO has initiated projects to integrate 3D printing into the joint logistics chain, especially in multinational or humanitarian missions. Countries such as Australia, India, China and Russia are also investing in military 3D printing, focusing on operational autonomy, advanced technology and cost reduction.
Innovation highlights in the military sector
ExOne and the manufacture of robust casingsExOne has been working on the development of strong and robust 3D printed factory pods for military use, using its Binderjet technology that allows the injection of more than 20 metallic, ceramic and other powdered materials.
ICON and 3D printed barracksICON, in partnership with the Texas Military Department, has built the largest 3D printed structure in North America: a 3,800 m² training barracks at the Camp Swift Training Center, capable of housing up to 72 soldiers.
SPEE3D and quick spare parts: The Australian Army has used SPEE3D technology to manufacture a dozen of its own spare parts for armoured vehiclesincluding a wheel bearing cover created in just 29 minutes at a total cost of 100 Australian dollars.
Combat helmets: General Lattice has signed a contract with the US Army to improve the impact attenuation of combat helmets through 3D printing and advanced mesh geometries. ASTRO America has been selected for the project. Jointless Hulla US military initiative to develop monolithic helmets for combat vehicles using 3D printing, with the aim of reducing both manufacturing times and production costs.
Printed runways: Indiana Technology and Manufacturing Companies has developed a runway for expeditionary military airfields using 3D printing, creating runway mats that are lighter and more durable than traditional aluminium runway mats.
Naval Group and ship propellersRead more : France's Naval Group has used 3D printing to manufacture a five-bladed 200 kg boat propeller, which was used on the minehunter Andromeda, drastically reducing construction time and minimising the amount of materials used.
Significant developments in Spain
April 2025, was inaugurated in Linares (Jaén) the Centre for the Development of Special Applications and Certification of Processes for the Military and Defence Sectors (CEDAEC), the first in Spain dedicated to the advanced manufacturing for the Armed Forces. This centre, which is the result of an agreement between the company Sicnova and the Ministry of Defence, is equipped with cutting-edge technology in 3D scanning, additive manufacturing and test labs, y will serve as a coordinating centre for facilities in Albacete, Rota and Cordoba.
In addition, the Spanish company Meltio has succeeded in expanding into the international defence market, with the validation of its metal 3D printing technology by the South Korean Army, marking its first foray into Asia. This certification follows previous validations by the US Navy, the French Navy and the Spanish Army and Air and Space Forces, as well as other European armies.
In this context, why is 3D printing key in the aerospace and military sector?
Because it allows a agile, adaptable and decentralised manufacturingThese qualities fit perfectly with the needs of the aerospace industry. From lightweight metal parts to complete structures, 3D printing is opening the door to a new paradigm in defence and aviation.
If you're looking to apply these innovations to your processes or projects, find out how we work at aerospace 3D printing and how we can help you to take a technological leap with solutions designed for the most demanding conditions.
