3D Systems is accelerating the expansion of its additive metal manufacturing business for aerospace and defense. For the Aerospace & Defense (A&D) segment, the company expects growth of more than 15 percent in 2025 and more than 20 percent in 2026. By 2026, revenue from production printing systems and custom-manufactured metal parts is expected to exceed USD 35 million.
As a political framework, the National Defense Authorization Act (NDAA) for fiscal year 2026 is having an impact. It includes provisions that restrict the use of foreign-sourced 3D printing systems in U.S. Department of Defense programs.
“Aerospace and defense customers worldwide increasingly require a reliable partner that delivers qualified, scalable solutions with speed, security, and supply chain resilience—supported by deep regional expertise and seamless global capabilities,” said Dr. Jeffrey Graves, president and CEO of 3D Systems. “Our Littleton expansion and strategic investments are significantly strengthening our U.S.-based Application Center of Excellence with advanced engineering, qualification-ready platforms, and expanded production capacity—dramatically accelerating the path from prototype to mission-critical deployment and improving outcomes for customers across our U.S., European, and international operations. Recent U.S. policy developments, including NDAA provisions, provide an additional tailwind that aligns closely with our ongoing domestic investments.”
Operationally, the Littleton (Colorado) site is at the center. In several phases, 3D Systems plans to add up to 80,000 square feet of additional space there and expand the Application Center of Excellence for application development, process qualification, validation, and production. The facility is to be certified under the America Makes JAQS-SQ program, which—together with partners such as NCDMM and NIAR—advances standardized qualification of additively manufactured defense components. For quality assurance, 3D Systems intends to leverage existing processes from medical technology; in Littleton, titanium implants have been produced on the DMP 350 for years, including traceability from powder batch to finished part.
“We are prioritizing A&D applications where additive manufacturing delivers maximum mission impact—from shipbuilding and advanced defense systems to aviation and space,” said Dr. Mike Shepard, vice president, aerospace & defense business at 3D Systems. “Our broad technology portfolio and ability to co-develop and efficiently scale critical applications have been key to our success.”
In parallel, 3D Systems is working on a multi-stage development program for large-format laser powder bed fusion, funded by the U.S. Air Force with USD 18.5 million. The goal is higher throughput and larger parts for structural and propulsion applications, with milestones running through 2027. Internationally, the company complements its U.S. activities with engineering in Leuven (AS9100), machine production in Riom, and an AS/EN 9100-certified joint venture in Saudi Arabia that aims to qualify and locally manufacture mission-critical components with Lockheed Martin. A&D Vice President Mike Shepard says the company prioritizes applications where additive manufacturing delivers measurable benefits in weight reduction, part consolidation, and lead time.
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