Defense Needs in the Additive Manufacturing Space

Adding manufacturing capabilities to the defense industry is changing the way military equipment, parts, and tools are produced. For small to mid-sized U.S. manufacturing companies, understanding the defense sector’s needs in additive manufacturing (AM) can open doors to new contracts, innovation, and long-term growth. But it’s also essential to know what security, quality, and reliability standards military clients expect. This article breaks down the key defense needs in additive manufacturing, what it takes to meet those needs, and how your business can position itself for success.

Why Additive Manufacturing Matters to Defense

Traditional manufacturing relies on subtractive processes — machining, casting, forging, etc. — which can be time-consuming, costly, and inflexible. Additive manufacturing, or 3D printing, builds parts layer-by-layer directly from digital models. This technology offers several advantages for defense applications:

• Rapid prototyping: Quickly test and refine designs without long lead times.

• On-demand production: Produce parts in the field or at remote locations, reducing logistics challenges.

• Complex geometries: Create parts that are impossible with traditional methods, like lightweight structures and integrated functions.

• Cost efficiency: Save on tooling and reduce waste.

However, to fully tap into the defense sector, manufacturers must meet rigorous standards around quality, security, and reliability.

Defense-Specific Requirements for Additive Manufacturing

1. Part Quality and Certification

Military applications often demand high-performance parts that can withstand extreme conditions—temperature, vibration, corrosion, and stress. To certify these parts, manufacturers need to follow strict quality control processes:

• Material Certification: Use certified materials that meet military specs.

• Process Validation: Demonstrate consistent manufacturing processes, often through third-party testing and documentation.

• Traceability: Maintain detailed records of each part’s origin, material batch, and manufacturing parameters.

2. Security Standards and Safeguards

Defense manufacturing involves sensitive data and intellectual property. The U.S. Department of Defense (DoD) emphasizes cybersecurity measures like:

• Secure Data Handling: Protect digital files, CAD models, and process data from hacking or theft.

• Access Controls: Limit access to authorized personnel with robust authentication systems.

• Cybersecurity Compliance: Align with standards like CMMC (Cybersecurity Maturity Model Certification) to ensure your systems are protected.

3. Supply Chain Resilience and Flexibility

Defense needs fluctuate based on strategic demands. Manufacturers must be able to:

• Adjust production quickly to meet new requirements or respond to crises.

• Work with multiple suppliers for critical materials, ensuring redundancy.

• Maintain inventory flexibility, possibly producing parts in-house or locally.

4. Integration with Existing Military Systems

Military equipment often involves complex assemblies with multiple parts. Additive manufacturing must be compatible, often requiring:

• Design for AM (DfAM) techniques to optimize part geometry.

• Meet interoperability standards for parts and materials.

• Test and validate parts within existing systems before large-scale deployment.

Getting Started: How Small to Mid-Sized Manufacturers Can Support Defense Needs

Assess Your Capabilities

First, identify if your current additive manufacturing processes meet the standards listed above. Consider:

• What materials can you print, and are they certified for military use?

• Can your process produce parts with the required tolerances and quality?

• Do you have cybersecurity measures in place to protect sensitive data?

Build the Right Certifications

Most defense contractors will expect certifications such as ISO 9001 for quality management and AS9100 for aerospace/defense quality standards. Additionally, pursuing cybersecurity standards like CMMC can make your business more attractive to defense clients.

Partner with Trusted Suppliers and Agencies

Collaborating with established defense contractors, government agencies, or suppliers familiar with military requirements can help you navigate certifications, testing, and compliance processes.

Invest in Testing and Validation

Don’t underestimate the importance of rigorous testing. Working with accredited labs and testing facilities ensures your parts meet all necessary standards and can be approved for military use.

Conclusion

For small and mid-sized manufacturers, the defense sector’s needs in additive manufacturing represent a promising growth area. The key is understanding what the military requires — high quality, traceability, security, and flexibility — and aligning your processes accordingly. With the right investments in certifications, cybersecurity, and testing, your company can become a trusted partner in supporting national defense while expanding your business capabilities.

To learn more about the standards and processes involved, visit the Defense Logistics Agency's Additive Manufacturing resources.

Remember: In the defense space, quality and security aren’t optional — they’re essential. Stay diligent, stay prepared, and your manufacturing expertise can make a real difference.