3D Metal Printing in the Defense and Firearms Industry

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Written By kim jes

Defense companies are embracing metal AM technology. They recognize production innovation and customization benefits, material efficiencies and reduced supply chain dependencies.

Metal 3D printing is achieved through direct metal laser solidification (DMLS). DMLS machines use a high-powered laser to melt and fuse powdered metal into fully dense parts. Support structures are always required to mitigate warping and distortion from the high processing temperatures.


The military is spending a lot of money to 3D print parts. For example, they are working with companies such as i3DMFG to develop Direct Metal Laser Solidification (DMLS), which can be used to make metal defense components. They hope to produce these parts at a fraction of the cost that would be involved in manufacturing them using traditional methods.

The technology is also expected to improve the speed at which replacement parts are produced, especially in emergency situations. Currently, the military must wait for replacement parts to be shipped from the manufacturer. However, with the new technology, replacements can be printed at the battlefield site, significantly reducing logistical costs and delays. Additionally, the technology will help to create more complex geometries and patterns that will improve the performance of military equipment.

As a result, the military will have more flexibility and be able to respond quickly to changing operational circumstances. Furthermore, it will be easier to maintain and upgrade legacy equipment. This will ultimately lead to more effective missions and a more lethal force.


Defense and aerospace manufacturers must often produce parts that can withstand harsh conditions, including high stress, heat, and corrosion. Many of these parts require metal – which can be difficult to machine. However, 3D printing has made it possible to fabricate parts from a wide range of alloys, including the incredibly strong and durable nickel-based superalloy Inconel 625.

Inconel 625 is used in aircraft, spacecraft, rockets and other critical equipment because it has great strength, stiffness, and corrosion-resistant properties. Traditionally, it has been difficult and expensive to machine. The 3D printing process makes it much easier to create Inconel components, allowing for more efficient production and lower costs.

The durability of 3D printed parts is largely dependent on the type of alloy used and the printing method. Directed energy deposition and binder jetting are two methods that can print metallic parts with impressive tensile strengths. However, these processes can also create defects in the finished product. One such defect is residual stress, which occurs when the resulting part experiences a change in direction or shape, such as a bend or twist. Residual stress is most severe at the interface between the printed part and the substrate on which it is attached.


With the ability to bring manufacturing to the frontlines, 3D printing in metal can reduce logistics and supply chain dependence. For example, the Army Research Laboratory (ARL) is working on a way for forward-deployed units to produce their own replacement parts, which can cut costs and speed up the delivery process.

In addition to the material properties that influence a printed part’s strength, there are several factors that can impact its reliability. One of the most important is the density of the print. The higher the print’s density, the more solid and durable it will be. Increasing the density of a printed part can be achieved by choosing different particle shapes. For instance, spherical particles have a greater density than flat ones.

To reduce these risks, a number of companies are offering machine-learning algorithms that can help identify the most reliable printing processes. These algorithms can also be used to optimize the design of a part, ensuring that it will print correctly. This can reduce the time and cost of a new product by eliminating the need for multiple iterations.


In a time of war, it is important for manufacturers to be able to quickly and easily produce replacement parts. This not only ensures that equipment is available to the troops, but it also reduces downtime and increases efficiency. Fortunately, 3D printing technology can help manufacturers do just that. With this technique, metal and plastic parts can be printed directly from digital designs, saving time and money.

As the technology advances, 3D metal printers are becoming increasingly affordable. In fact, they can be bought for under $200 on Amazon. This has lowered the barrier to entry for individuals who want to print weapons, and has led to an increase in the number of untraceable firearms found at crime scenes. However, there is hope that the technology can be controlled to prevent its use for illicit purposes.

While the advantages of metal 3D printing are clear, it’s important to remember that this technology could be used by terrorist groups to fabricate weapons. Currently, there are no laws preventing terrorists from using 3D printing to manufacture weapons. In the future, this technology could become more prevalent, and it is important for governments to regulate its use. Moreover, the proliferation of this technology could lead to the development of new weapons that are more powerful and accurate than conventional weapons.

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