As part of a joint project between the Forward Deployed Regional Maintenance Center (FDRMC) Detachment Rota and the Spanish Navy, additively manufactured components were installed on board the destroyer USS Arleigh Burke (DDG 51) for the first time at the beginning of June. The aim of the measure was to ensure the ship’s operational readiness ahead of a planned patrol in the US Sixth Fleet’s area of responsibility.
Specifically, two so-called eductors – jet pump-like components of the vacuum sewage system (VCHT) – were replaced with 3D-printed spare parts. The previous components had leaks that had only been provisionally sealed. According to FDRMC, it would have taken almost a year to reproduce these parts conventionally from cast bronze. However, thanks to the additive manufacturing approach, the time frame was reduced to around two months, including planning and installation. The actual production of the spare parts from corrosion-resistant stainless steel wire took just seven days.
“We have empowered and equipped our waterfront and forward-deployed engineers and maintainers that directly support our warfighters,” said Rear Adm. Pete Small, NAVSEA chief engineer. “This project executed with our Spanish allies further proves the significant readiness AM generates for our ships, restoring a critical system while meeting the compressed timeline for the ship’s forward-deployed patrol.”
This accelerated process was made possible by an updated approval guideline from the Naval Sea Systems Command (NAVSEA). This allows local technical officers to approve low-risk AM components independently, eliminating bureaucratic hurdles.
“FDRMC is the front-line readiness generator for our forward deployed naval forces in Fifth and Sixth Fleets,” said Capt. Mollie Bily, FDRMC commanding officer. “Our Rota AM team attacks each maintenance window looking for a way to use advanced AM to expedite parts and solutions for our homeported and deployed ships that must be ready for Fleet tasking at a moment’s notice.”
Since the directive was introduced in 2023, 37 additively manufactured components have already been permanently installed in the fleet. The current project with Spanish participation shows how AM processes are increasingly finding their way into maritime logistics – especially where supply chains are limited or response times are critical.
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