US defense programs promote materials and AI research for industrial 3D printing

The U.S. organizations America Makes and the National Center for Defense Manufacturing and Machining have launched two new funding calls with a total volume of eight million U.S. dollars. Both programs address key challenges in metal 3D printing, particularly in the context of safety-critical applications and regulated supply chains.

The larger share of the funds flows into the PADAM 2.0 program, which is financed by the Materials and Manufacturing Directorate of the Air Force Research Laboratory . The goal is to further develop high-temperature-resistant refractory alloys for additive manufacturing processes. This class of materials is considered difficult to process but offers advantages for defense applications due to its temperature and creep resistance. The funded projects are intended to generate robust process data, increase the stability of additive manufacturing processes, and improve the qualification of components. At the same time, supply chain resilience is a key focus, from raw material extraction to the qualified end component, which is of strategic importance for the Department of Defense.

A second funding call, designated AIM-4AM, is supported by the Office of the Under Secretary of Defense Manufacturing Technology Office. This program focuses on the use of machine learning methods to determine material properties for additively manufactured 17-4PH stainless steel produced using the laser powder bed fusion process. Based on process–structure–property models, testing efforts are to be reduced and remaining risks made quantifiable.

Representatives of the participating organizations emphasize that both programs aim to facilitate the transition from research to industrial application. For companies and research institutions, this creates an opportunity to further validate the use of 3D printing processes under realistic production conditions.