Expeditionary Manufacturing Unit (EMU), Image: SPEE3D
SPEE3D is an Australian company specializing in high-speed metal additive manufacturing. Its patented CSAM technology utilizes a unique cold spray process to produce metal components quickly and efficiently without the need for melting. This approach enables the rapid production of durable metal parts, making it particularly suited for industrial, defense, and aerospace applications. In an interview with 3Druck.com, Defense Lead Calum Stewart talks about the impact of additive manufacturing, especially in defense, discusses advancements in metal 3D printing, and examines challenges of high-speed printing in demanding environments.
One of their key systems is the Expeditionary Manufacturing Unit (EMU), an integrated defense solution that combines the XSPEE3D printer with the SPEE3Dcell post-processing unit. Designed for deployment in remote or operational environments, the EMU enables end-to-end metal part production in the field, providing armed forces with a mobile, self-contained manufacturing capability. Unlike fusion-based metal additive manufacturing methods, which rely on high-powered lasers or electron beams to melt and solidify powder layers, Cold Spray Additive Manufacturing (CSAM) uses kinetic energy to bond particles, eliminating thermal distortions and reducing material constraints. These particles bond upon impact, forming solid metal structures within hours, significantly reducing production times compared to traditional manufacturing techniques.
SPEE3D’s technology is applied across various industries, including defense, maritime, and industrial manufacturing. It has worked with the Australian Army to deploy its printers in field environments, enabling on-demand production of spare parts. The company has also tested its printers in extreme environments, successfully fabricating metal components at sub-zero temperatures, demonstrating their reliability in harsh operational settings.
To expand its reach, SPEE3D has established a production facility and application center in the United States. This expansion allows the company to manufacture its 3D printers closer to the North American market while working closely with customers to develop tailored applications. As additive manufacturing continues to evolve, SPEE3D’s focus on speed, efficiency, and adaptability positions its technology as a valuable solution across multiple industries. With advancements in automation and large-scale printing on the horizon, the company’s approach could further expand the capabilities of metal 3D printing in industrial and defense applications.
Interview with Calum Stewart
In an interview with 3Druck.com, SPEE3D’s Defense Lead Calum Stewart discusses the growing role of additive manufacturing (AM) in defense, key technological advancements, and the evolving needs of modern military logistics. He also outlines challenges in deploying high-speed 3D printing in demanding environments and offers insights into SPEE3D’s ongoing development strategy.
What role does additive manufacturing play in transforming industries—particularly in sectors like defense, where SPEE3D plays a significant role?
Defense Lead Calum Stewart
Additive manufacturing is transforming defense capabilities by enabling faster production, lowering costs, enhancing performance, and strengthening supply chain resilience. It improves warfighter readiness by allowing for on-demand production of spare parts and repairs. Additionally, it reinforces supply chain security through decentralized and resilient manufacturing processes. The technology also advances next-generation defense equipment by enabling the production of stronger, lighter, and more efficient weapons and vehicles. Furthermore, it integrates digital transformation, paving the way for AI-driven smart manufacturing.
Looking at the U.S. Department of Defense’s Regional Sustainment Framework and the UK’s Additive Manufacturing National Strategy, it’s clear that the logistics and supply of engineering support materials—whether spare parts, tools, or components—must be responsive, agile, and robust. This isn’t just about AM companies selling stand-alone technology. The defense sector requires full solutions that account for training, equipment, personnel, infrastructure, doctrine, and logistics. Without addressing all of these areas, the industry cannot provide what defense truly needs.
Additive manufacturing has advanced significantly in recent years. Which innovations or technological breakthroughs do you consider particularly transformative?
In recent years, several key innovations have significantly shaped the progress of additive manufacturing. High-speed and large-scale AM technologies have greatly improved production efficiency. The development of next-generation materials and multi-material printing has expanded the possibilities for more complex and durable components. Additionally, the integration of digital systems has enabled real-time processing, improved traceability, and enhanced repeatability and data security. Hybrid manufacturing—combining additive and subtractive processes—has also gained traction. Meanwhile, more sustainable approaches are being explored to reduce material waste and energy consumption.
What challenges arise when implementing high-speed 3D printing solutions in demanding environments, such as the military or maritime sectors?
There are numerous operational and environmental challenges. Harsh climates, extreme temperatures, and contamination can disrupt the printing process. Vibration and movement pose additional problems for machine stability, especially in field conditions. Material availability can be limited, and ensuring structural integrity and consistent print quality is vital. Post-processing and finishing remain complex tasks. Logistics and supply chain interruptions—particularly in feedstock delivery—can significantly impact mission readiness. Additionally, certification, standardization, and compliance requirements must be met. Power limitations, cybersecurity concerns, and the need for interoperable systems also play major roles.
At this moment in time, there’s an increased sense of urgency to deliver full solutions that include both hardware and software. Solutions in the military context translate to real capability—something that involves far more than just machines. It includes training personnel, integrating infrastructure, and aligning with operational doctrine and logistical systems. As an industry, AM must collaborate to deliver complete, deployable solutions that take advantage of the government funding available today. That also means investing in people who understand both the language and the operational context to design solutions that actually address real-world problems.
What future developments does SPEE3D plan for its printing technology, and how do you see the role of 3D printing in industrial manufacturing over the next five to ten years?
SPEE3D launched its large-format printer, the TitanSPEE3D, last year and is currently working on its commercialization. This system is intended for the production of very large metal parts and represents a major step forward in field-deployable industrial capability. In parallel, the company is updating its software to include artificial intelligence and more advanced automation to streamline production workflows.
There is no “silver bullet,” but action is needed now. If we’re not equipped to supply our militaries with the urgency of wartime logistics, we’re not practicing deterrence. A slow, bureaucratic supply chain cannot support operational readiness. Engineers and military personnel must be empowered to take calculated engineering risks—because with additive manufacturing, perfection isn’t always the goal. The objective is to get equipment back into the fight—quickly and effectively.
This shift also requires skills—not just machines. We need CNC machinists, technicians who understand heat treatment, and people trained in digital manufacturing. Soldiers are already being trained in this across Ukraine, Australia, the UAE, and Japan. The skills gap must be addressed. This isn’t just about 3D printing—it’s about manufacturing.
Back in WWII, the answer was foundries and forges. Those don’t exist at scale anymore. Today, engineers will turn to digitized, advanced additive—and subtractive—manufacturing to fill that gap. And as an industry, it’s time to step up and deliver.
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