The use of additive manufacturing technologies in a military context continues to grow in importance. Two US Army soldiers recently used the knowledge they acquired at the Naval Aviation School for Additive Manufacturing (NASAM) to manufacture mission-critical components on site during an overseas deployment of the Combined Joint Task Force – Operation Inherent Resolve.
Specialist James Martin and Specialist Harry Vo, both members of the 10th Mountain Division’s Allied Trades Team, developed a functional mount for antennas of the Starshield communication system used on protected vehicles of Task Force Wolverine. A missing mounting component was limiting the use of the system. The two soldiers then designed a solution that ensured both the mechanical stability and operational safety of the vehicles. The printed component allowed for favorable antenna positioning while reducing susceptibility to damage without compromising the functionality of the turret and emergency exit.
“This successful cross-service training demonstrates how AM capabilities can provide immediate solutions to operational challenges across the Department of Defense,” said Theodore Gronda, NAVAIR’s AM program manager. “When supply chains can’t deliver, AM delivers.”
For the prototype, Martin and Vo used acrylonitrile-styrene-acrylate (ASA), a UV and heat-resistant engineering plastic. Although this material was not part of the NASAM training, the two were able to flexibly apply their knowledge to the new material and system. The use of 3D printing not only reduced the manufacturing effort, but also the costs considerably.
“AM’s mission is to improve operational readiness and lethality,” said Capt. Alexander Peabody, senior fleet liaison for NAVAIR AM. “The reality is that even during peacetime, supply chain disruptions necessitate the ability to reverse engineer or redesign components to maintain the operational capability of ships and aircraft.”
While NASAM training is primarily designed for Navy and Marine Corps personnel, it is also open to other branches of the armed forces. The aim of the six-week program is to enable repair forces to manufacture the required components close to their location and as needed – especially in the event of unforeseen shortages.
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