Closeup of 3D printer working on prototype in APL lab

Rapid Prototyping

APL specializes in rapid prototyping, delivering high-quality, mission-critical solutions to address complex national challenges. By leveraging advanced manufacturing, AI-driven design, and precision fabrication, we rapidly design, fabricate, test, and deploy cutting-edge prototypes to address challenges in defense, space, and beyond, ensuring operational readiness with speed and precision.

Our expertise spans additive manufacturing, advanced materials, and automation, enabling the swift transition of concepts into functional systems while reducing technical risk and development time for sponsors and partners. Whether optimizing mission planning tools or developing autonomous systems for complex environments, we ensure that our solutions meet rigorous performance and reliability standards—allowing decision-makers to explore and implement emerging capabilities faster.

Expertise in Action

Highlights

Creating Coatings for Extreme Environments

The leading edges of hypersonics vehicles—as well as fins, control surfaces, and apertures—need to be protected against speeds exceeding Mach 5, temperatures well above 1,000 degrees Celsius, oxidation from the atmosphere, and tremendous aerodynamic shear loads. Custom materials can enable mission success in these extreme environments.

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Closeup of person's hands at keyboard and using CAD tool (Credit: Bigstock)

Rapid Prototyping for Launcher Training

We improved on training aids by rapidly and cost-effectively prototyping an interactive pressurization valve for missile tube launcher training.

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September 18, 2013: An SM-3 Block 1B interceptor is launched from the USS Lake Erie during an MDA test and successfully intercepted a complex short-range ballistic missile target off the coast of Kauai, Hawaii. (Credit: MDA)

Test Target Prototyping

A cross-APL team of engineers, working with the Missile Defense Agency’s (MDA) Target and Countermeasures Directorate and other government and industry partners, develops cost-effective solutions for MDA to support live-fire testing of interceptors, sensors, and fire control systems.

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Shape-Shifting Antenna for Adaptive Communications

By leveraging cutting-edge additive manufacturing techniques and shape memory alloys, APL researchers have created an antenna that can change its shape based on its temperature.

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Related Expertise and Facilities

Design, Engineering, and Fabrication

At APL, our culture of taking bold risks, brought to life through inventive prototyping and informed by deep technical expertise, is the basis for our efforts to not merely anticipate the future, but create it. Learn more about APL’s design, engineering, and fabrication capabilities.

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Battlefield medic views an overlay of a patient's internal anatomy

Revolutionizing Battlefield Medicine: Augmented Reality for Lifesaving Trauma Care Feb 13, 2025

Johns Hopkins APL researchers are leveraging predictive anatomy visualization, artificial intelligence and real-time ultrasound to help medics provide faster and more accurate medical care in the field.

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High-tech eye exam (Credit: Adobe Stock)

At-Home ‘Retinal Selfies’ May Provide a Window on Health Jan 16, 2025

Researchers at Johns Hopkins APL and the Johns Hopkins Medicine Wilmer Eye Institute in Baltimore are designing a retinal imaging platform in the form of wearable eyeglasses that has the potential to expand access to retinal imaging and generate enough data to train machine learning models for accelerated research and improved diagnostic capabilities.

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Nimble Cellular Networks Keep Tactical Users Connected Jan 7, 2025

Johns Hopkins APL researchers are contributing to the development of a mobile cellular system that can be installed in a small uncrewed aerial vehicle to give warfighters and first responders communications connectivity in austere environments.

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Shape-shifting antenna developed by Johns Hopkins APL researchers

Shape-Shifting Antenna Poised to Transform Communications Nov 26, 2024

Johns Hopkins APL researchers have leveraged cutting-edge additive manufacturing techniques and shape memory alloys to create an antenna that can change its shape — and offers a range of potential commercial, military and scientific applications.

Learn more about Shape-Shifting Antenna Poised to Transform Communications