Two U.S. Army soldiers deployed with Combined Joint Task Force Operation Inherent Resolve applied additive manufacturing (AM) training from a naval aviation program to produce critical components in the field. Their actions demonstrate how cross-branch technical instruction supports operational readiness.
SPC James Martin and SPC Harry Vo, part of the 10th Mountain Division’s Allied Trades Team (Bravo Company, 10th Brigade Support Battalion, 1st Brigade Combat Team), applied skills learned at the Naval Aviation School for Additive Manufacturing (NASAM) to address a shortage affecting communications systems. Task Force Wolverine lacked antenna mounts for mine-resistant ambush protected (MRAP) vehicles equipped with Starshield systems. Martin and Vo designed and 3D printed a mounting bracket that met all operational requirements. The bracket allowed proper antenna placement, reduced risk of damage, maintained full functionality of the emergency hatch and turret, and maximized connectivity.
The prototype was produced using acrylonitrile styrene acrylate, a durable polymer with UV and heat resistance. While this material was not covered in their NASAM coursework, the training provided a foundation that helped them adapt to different systems and materials. Their solution reduced manufacturing time and cost. “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 AM program manager. “When supply chains can’t deliver, AM delivers.”
NASAM, hosted by the Institute for Advanced Learning and Research in Danville, Virginia, provides a six-week program focused on AM fundamentals. It primarily serves Navy and Marine Corps personnel but occasionally trains members from other military branches. The program teaches maintenance personnel how to produce parts on site when supply chains are unable to deliver. “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.”
NASAM launched in February 2024 with a pilot cohort of 12 students. It continues to train military maintenance personnel in AM technologies. The experience of Martin and Vo shows how this training can be applied during active deployment to resolve logistical gaps.
Field-Deployed Additive Manufacturing in Military Operations
In 2024, the Indian Army collaborated with Simpliforge Creations and IIT Hyderabad to complete Project PRABAL, building a 3D printed military-grade bunker on-site at 11,000 feet in Leh. The team deployed a customized robotic 3D printing system and used locally sourced materials under high-altitude, low-oxygen conditions. The bunker’s form was optimized for structural strength, and the printing process lasted 14 hours, with full project completion in five days. The initiative followed multiple failed attempts by other teams to build in the region due to environmental constraints and demonstrated the feasibility of producing protective infrastructure directly in operational terrain.
The U.S. Department of Defense tested a similar forward-use application with SPEE3D’s Expeditionary Manufacturing Unit during its Point of Need Challenge. The XSPEE3D system was deployed at the Cold Regions Research and Engineering Laboratory in New Hampshire, where it produced metal components—including tools and vehicle replacement parts—at temperatures as low as -20°C. Additional parts were introduced during the live exercise to assess in-field adaptability. Post-trial testing at the New Jersey Institute of Technology confirmed that the printed components met material strength standards with minimal changes in ductility.
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Featured image shows Soldiers from the U.S. Army conduct operational checks and driver’s training using MRAP vehicles. Photo via U.S. Army.
