Machinery Repairman 1st Class Cory Hover demonstrates the software used to design the sprayer plate

Enhancing Naval Readiness with Onboard 3D Printing Solutions

Our Contribution

Additive Manufacturing Afloat

Naval vessels often face challenges in maintaining operational readiness due to the unavailability of critical components while at sea, leading to potential mission delays and costly returns to port for repairs.

APL, in partnership with the Naval Surface Force Atlantic and Naval Sea Systems Command (NAVSEA) Technology Office, installed the first hybrid metal 3D printer aboard the USS Bataan (LHD 5) in October 2022. This advanced system combines additive manufacturing (3D printing) with traditional subtractive methods, allowing for the efficient production of mission-critical components directly on the ship. In a notable instance, sailors utilized this technology to fabricate a stainless steel sprayer plate used to repair one of the ship’s deballasting air compressors, completing the process in under five days and avoiding an unscheduled return to port.

APL is collaborating with the Navy to advance in situ monitoring technologies for additive manufacturing, aiming to enhance the quality and reliability of 3D-printed components.

Related Areas of Impact

Mission Area

APL is uniquely positioned to respond to this challenge because of the breadth of expertise at the Lab. Where our Sea Control Mission Area excels at understanding the Navy’s needs and developing solutions to address those needs, our teammates in the Research and Exploratory Development Department have the deep technical knowledge necessary to make those solutions a reality.

Ed Chapman Assistant Manager, Maritime Expeditionary Warfare Program Area
Ed Chapman
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Related Expertise

Additive ManufacturingMechanical FabricationRapid PrototypingShip DefenseSystems Engineering
Related Areas of Impact

Mission Area