Close Menu
AM ChronicleAM Chronicle
  • Content
    • News
    • Insights
    • Case Studies
    • AM Infocast
  • Focus Regions
    • India
    • Asia Pacific
    • Middle East
    • North America
    • Europe
  • Industries
    • Automotive
    • Aerospace
    • Defence
    • Energy
    • Construction
    • Healthcare
    • Tooling
    • Engineering
  • Training
  • Magazine
    • Digital Issues
    • Print Subscription
  • Events
Facebook Instagram YouTube LinkedIn
  • About us
  • Media Kit
  • Contact us
Facebook Instagram YouTube LinkedIn
AM ChronicleAM Chronicle
  • Content
    1. News
    2. Insights
    3. Case Studies
    4. AM Infocast
    5. View All
    Velo3D enters CRADA with NAVAIR to Advance Additive Manufacturing for Aerospace and Defense Applications, Credits: Velo3d

    Velo3D enters CRADA with NAVAIR to Advance Additive Manufacturing for Aerospace and Defense Applications

    June 5, 2025
    Novel Magnetic 3D-Printed Pen

    Novel Magnetic 3D-Printed Pen Can be A Promising Diagnostic Tool for Early-Stage Parkinson’s Disease

    June 3, 2025
    Caption:Researchers have developed a resin that turns into two different kinds of solids, depending on the type of light that shines on it: Ultraviolet light cures the resin into a highly resilient solid, while visible light turns the same resin into a solid that is easily dissolvable in certain solvents. Credits:Credit: Courtesy of the researchers; MIT News

    New 3D printing method by MIT enables complex designs and creates less waste

    June 3, 2025
    NAMI Partners with Ministry to Launch Saudi Arabia’s Advanced Manufacturing Centre

    NAMI Partners with Ministry to Launch Saudi Arabia’s Advanced Manufacturing Centre

    May 30, 2025
    Revopoint Trackit Now on Kickstarter: Marker-free 3D Scans Within Everyone's Reach!

    Revopoint Trackit Now on Kickstarter: Marker-free 3D Scans Within Everyone’s Reach!

    May 28, 2025
    Credits: Outokumpu

    Outokumpu launches stainless steel metal powder in additive manufacturing for aerospace and aviation industry applications

    May 22, 2025
    Why Bioprinting Innovations can elevate healthcare and industrial AM

    Why Bioprinting Innovations can elevate healthcare and industrial AM

    May 21, 2025
    Why Additive Manufacturing Excels in Some Applications but Fails in Others?

    Why Additive Manufacturing Excels in Some Applications but Fails in Others?

    May 21, 2025
    Formlabs fuse 1+

    How Imaginarium Helped Kaash Studio Scale with the Right 3D Printing Technology

    April 12, 2025
    The Formlabs Fuse 1+ 30W

    Kaash Studio Optimized Service Bureau Operations with Formlabs 3D Printers- Case Study

    January 30, 2025
    Namthaja Unveils Worlds First 3D Printed Marine Gangway

    Worlds First 3D Printed Marine Gangway unveiled by Namthaja

    August 8, 2024
    RusselSmith Material Performance Improvement Whitepaper

    RusselSmith Whitepaper : Improving Material Performance with Microstructural Refinement

    May 9, 2024
    Sustainable Production of Metal Powder for Additive Manufacturing

    Sustainable Production of Metal Powder for Additive Manufacturing with Bruce Bradshaw

    February 15, 2024
    Meeting Evolving Customer Demands in the Additive Manufacturing Industry with Tyler Reid

    Meeting Evolving Customer Demands in the Additive Manufacturing Industry with Tyler Reid

    February 9, 2024
    Innovation is at the heart of AMUG with Diana Kalisz

    Innovation is at the heart of AMUG with Diana Kalisz

    March 7, 2023
    3D Printing Workshops at AMUG with Edward Graham

    3D Printing Workshops at AMUG with Edward Graham

    March 7, 2023
    Velo3D enters CRADA with NAVAIR to Advance Additive Manufacturing for Aerospace and Defense Applications, Credits: Velo3d

    Velo3D enters CRADA with NAVAIR to Advance Additive Manufacturing for Aerospace and Defense Applications

    June 5, 2025
    New 3D Printing Technology Enables Dual-Material Creation from Single Resin

    New 3D Printing Technology Enables Dual-Material Creation from Single Resin

    June 5, 2025
    Novel Magnetic 3D-Printed Pen

    Novel Magnetic 3D-Printed Pen Can be A Promising Diagnostic Tool for Early-Stage Parkinson’s Disease

    June 3, 2025
    Caption:Researchers have developed a resin that turns into two different kinds of solids, depending on the type of light that shines on it: Ultraviolet light cures the resin into a highly resilient solid, while visible light turns the same resin into a solid that is easily dissolvable in certain solvents. Credits:Credit: Courtesy of the researchers; MIT News

    New 3D printing method by MIT enables complex designs and creates less waste

    June 3, 2025
  • Focus Regions
    • India
    • Asia Pacific
    • Middle East
    • North America
    • Europe
  • Industries
    • Automotive
    • Aerospace
    • Defence
    • Energy
    • Construction
    • Healthcare
    • Tooling
    • Engineering
  • Training
  • Magazine
    • Digital Issues
    • Print Subscription
  • Events
Subscribe
AM ChronicleAM Chronicle
Home » Case Studies

US Army uses Additive Manufacturing low volume replacement parts

Case Studies By AM Chronicle EditorMarch 28, 20224 Mins Read
US Army uses Additive Manufacturing low volume replacement parts
LinkedIn Twitter Facebook WhatsApp Pinterest Email Copy Link

A major training base for the U.S. Army provides realistic joint and combined arms training to develop the U.S. Army’s soldiers and leaders for the battlefield. They train soldiers for upcoming deployments, wherever that may be in the world.

By using additive manufacturing technology, the Army is able to create readiness factors that decrease downtime.

The Challenge

“Readiness” is a term the U.S. Army often uses, which refers to the need for troops, formations, and equipment to perform under the pressures of military operations. They constantly strive to increase readiness by innovating faster and better than other military groups around the world.

The military-grade vehicles and equipment that are critical for mission support endure a tremendous amount of wear and tear. If a part breaks, soldiers have fewer resources to use at the training center, as lead times for replacement parts are as long as three months due to the facility’s remote location. The process is long and inefficient as well as costly, and a single part breaking can have severe ramifications on a squadron.

Markforged X7
A US Army soldier uses a Markforged X7

The Solution

There are currently 10 centers in the U.S. that focus on specific areas to train soldiers and servicemembers. In late 2019, after researching various types of 3D printers, one training base brought in two Markforged X3 industrial 3D printers and one Mark Two desktop 3D printer. The regiment needed durability, functionality, and versatility — and Markforged machines’ Continuous Fiber Reinforcement (CFR) printing process gives them the ability to print with continuous carbon fiber, fiberglass, and Kevlar®. The U.S. Army’s Markforged composite printers have been used for personal protective equipment (PPE), window wiper brackets for military vehicles, tools, and low-volume production parts.

The regiment has also started to 3D print a critical low-volume replacement part for a component that is no longer available: a hatch plug that sits on top of a vehicle used in low-light scenarios. The hatch plug helps the driver see at night, giving the driver the ability to tell the soldiers to engage. Unfortunately, this part is not in production anymore, and would cost roughly $10,000 to reproduce, not to mention the 3-month lead time. With Markforged, the regiment printed the hatch plug in Markforged Onyx material for $230, and then another using 17-4PH Stainless Steel on the Metal X for $800. This application alone has saved the regiment $244,000.

The regiment has saved a significant amount of time and money with Markforged printers, but they have also simplified the hatch plug with fewer components. It’s now an easier, simpler product — the previous design comprised ten parts, but is now down to four. The U.S. Army base intends to continue printing tooling and fixtures, as well as small production parts with traditionally long lead times, to ensure their soldiers are able to properly utilize the resources at the center.

Along with the printers, Eiger — Markforged’s powerful slicing software — has been beneficial for the regiment and Soldiers. Users within the regiment have seen the benefits of the Digital Forge platform, and have found the software to be highly optimized for both the printers and the platform. While other additive manufacturing software platforms are free rein when it comes to choosing temperatures and speeds, Eiger has an optimized, hands-off approach that works with their machines, resulting in higher-quality parts.

on demand 3d printed parts

The Future

This U.S. Army training center has been utilizing Markforged printers since early 2020, with plans to bring in more additive manufacturing capabilities. Markforged University also plays a big role in the U.S. Army’s readiness by training soldiers how to properly use the Markforged platform. Getting several soldiers certification on Markforged software and printers is a significant value add for the U.S., as without a proper understanding of how to best use Markforged technology, the team may not be as effective at designing parts for additive manufacturing.

The training center’s use of Markforged technology has become a catalyst for other similar centers around the U.S., who have come to visit to get an idea of what is possible.

Original Source

Subscribe to AM Chronicle Newsletter to stay connected:  https://bit.ly/3fBZ1mP 

Follow us on LinkedIn: https://bit.ly/3IjhrFq 

Visit for more interesting content on additive manufacturing: https://amchronicle.com/

3d printing additive manufacturing Automotive Defence Engineering Markforged X7 Military USA
AM Chronicle Editor

LATEST FROM AM
Velo3D enters CRADA with NAVAIR to Advance Additive Manufacturing for Aerospace and Defense Applications, Credits: Velo3d News

Velo3D enters CRADA with NAVAIR to Advance Additive Manufacturing for Aerospace and Defense Applications

June 5, 20252 Mins Read
New 3D Printing Technology Enables Dual-Material Creation from Single Resin Uncategorized

New 3D Printing Technology Enables Dual-Material Creation from Single Resin

June 5, 20251 Min Read
Novel Magnetic 3D-Printed Pen News

Novel Magnetic 3D-Printed Pen Can be A Promising Diagnostic Tool for Early-Stage Parkinson’s Disease

June 3, 20253 Mins Read

CONNECT WITH US

  • 126 A, Dhuruwadi, A. V. Nagvekar Marg, Prabhadevi, Mumbai 400025
  • [email protected]
  • +91 022 24306319
Facebook Instagram YouTube LinkedIn

Newsletter

Subscribe to the AM Chronicle mailer to receive latest tech updates and insights from global industry experts.

SUBSCRIBE NOW

Quick Links

  • News
  • Insights
  • Case Studies
  • AM Training
  • AM Infocast
  • AM Magazine
  • Events

Media

  • Advertise with us
  • Sponsored Articles
  • Media Kit

Events

  • AM Conclave 2025
    24-25 September 2025 | ADNEC, Abu Dhabi
  • AMTECH 2025
    3-4 December 2025 | KTPO, Whitefield, Bengaluru
CNT Expositions & Services LLP
© 2025 CNT Expositions & Services LLP.
  • Privacy Policy
  • Cookie Policy

Type above and press Enter to search. Press Esc to cancel.



0 / 75