U.S.-based 3D printer manufacturer 3D Systems has reported notable developments in its Aerospace & Defense (A&D) segment, driven by revenue growth projections, a major U.S. facility expansion, and technological advancements.
These initiatives aim to meet rising demand for secure domestic manufacturing in national security and space programs, a trend supported by the Fiscal Year 2026 National Defense Authorization Act (NDAA), which restricts foreign-sourced 3D printing systems for Department of Defense (DoD) programs.
Revenue Outlook and Market Position
After several years of growth, the A&D division is expected to become 3D Systems’ largest and fastest-growing industrial business in 2026, serving applications across crewed and uncrewed aircraft, naval platforms, defense systems, rocket propulsion, and satellites.
The A&D business is forecast to have grown over 15% in 2025, with expectations to exceed 20% growth in 2026. Revenue from production printing systems and custom metal parts is projected to surpass $35 million in 2026. Growth is supported by adoption in high-reliability defense and space programs, along with additional demand generated by NDAA provisions.
“Aerospace and defense customers worldwide increasingly require a reliable partner that delivers qualified, scalable solutions with speed, security, and supply chain resilience—supported by deep regional expertise and seamless global capabilities,” said Dr. Jeffrey Graves, president and CEO of 3D Systems.
Facility Expansion and Domestic Manufacturing
3D Systems is expanding its Littleton, Colorado facility by up to 80,000 square feet, enhancing the A&D Application Center of Excellence. The expanded space will support application development, process qualification, validation, and production-scale manufacturing, contributing to domestic supply chain resilience and faster innovation. The facility is also pursuing certification under the America Makes JAQS-SQ framework in collaboration with the National Institute for Aviation Research (NIAR), enabling qualified additive manufacturing production for defense components.
The Littleton expansion strengthens 3D Systems’ capacity to co-develop solutions with customers in areas including supply chain resilience, new application development, robust printing solutions, and propulsion/casting applications.
“We are prioritizing A&D applications where additive manufacturing delivers maximum mission impact—from shipbuilding and advanced defense systems to aviation and space,” said Dr. Mike Shepard, vice president, aerospace & defense business at 3D Systems. “Our broad technology portfolio and ability to co-develop and efficiently scale critical applications have been key to our success.”
The company is also progressing a multi-phase, $18.5 million U.S. Air Force-sponsored program to develop next-generation laser powder-bed fusion technologies for large-format, high-efficiency metal parts. These technologies are designed to support a growing range of defense applications and remain on track through 2027.
Latest Advancements by 3D Systems in Aerospace and Defense
In August, 3D Systems secured a $7.65 million contract from the U.S. Air Force to further develop its Large-Format Metal 3D Printer Advanced Technology Demonstrator (GEN-IIDMP-1000). This two-year award builds on a program that began in 2023, focused on expanding AM capabilities for producing large, high-temperature metal structures tailored for high-speed flight applications.
In July, 3D Systems’ Application Innovation Group (AIG) began collaborating with researchers at Penn State University (PSU), Arizona State University (ASU), and NASA Glenn Research Center to develop next-generation thermal management solutions for spacecraft. These NASA-supported projects leverage 3D Systems’ Direct Metal Printing (DMP) technology in combination with Oqton’s 3DXpert software to produce high-performance radiators and heat pipes from titanium and nickel-titanium alloys, enabling lighter, more efficient, and robust thermal systems for space missions.
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Featured image shows 3D Systems at Formnext 2025. Photo via 3D Systems.
