U.S. provider of composite shelter systems SelectTech Services Corporation has unveiled ForgeX, a fully expandable composite shelter created with American defense and aerospace firm AEVEX. The new system houses a climate-controlled additive manufacturing setup built for field environments where permanent facilities are scarce.
ForgeX allows military units and remote industrial teams to fabricate mission-critical tools, replacement parts, and even unmanned aircraft directly on site, cutting supply-chain delays and strengthening operational flexibility.
“ForgeX is a clear extension of AEVEX’s mission to deliver adaptable, expeditionary solutions at speed,” said Roger Wells, chief executive officer of AEVEX. “By combining our digital engineering, unmanned systems expertise and additive manufacturing capabilities with SelectTech’s composite shelter technology, we are enabling forward-deployed forces to produce and sustain critical capabilities where and when they are needed most.”
Core Capabilities and Partner Perspectives
The ForgeX module is engineered for mobility and autonomy. Constructed from lightweight composites, it is 463L pallet-ready, weighs under 10,000 pounds, and can be opened and operational within minutes, expanding into a 320 sq ft workspace.
The shelter can run independently from local infrastructure, thanks to an integrated generator option paired with a 100-amp power configuration, and includes Starlink connectivity for data and communications. Inside, users have access to configurable printers loaded with pre-set digital files for components such as drones. All networking, computing, and storage elements are enclosed within the shelter, and every component is commercially sourced from U.S. suppliers.
“In today’s contested environments, waiting days or weeks for a critical replacement part is no longer an option,” said Curran Mulvihill, vice president of operations and strategy at SelectTech. “Our new 3D printing workshop puts the power of sophisticated manufacturing directly into the hands of a warfighter or remote technician. It’s light, expandable and fully mission-capable off-grid, embodying true expeditionary logistics.”
Secure, On-Demand 3D Printing Gains Traction in Defense
Defense stakeholders globally are increasingly turning to additive manufacturing to bolster readiness. Reflecting this trend, Netherlands-based 3D printer maker UltiMaker has launched its Secure Line, including the S6 Secure and S8 Secure, targeting defense and high-security environments. Built on the S series platform, the systems are designed for tactical deployments on land, sea, and air, enabling trusted, on-demand manufacturing in mobile units, military bases, and naval operations. Enhanced cybersecurity features ensure compliance with modern defense IT standards, reinforcing the move toward secure, distributed additive manufacturing across global defense forces.
Similarly, at Project Convergence-Capstone 5 (PC-C5), Firestorm’s xCell system demonstrated on-site expeditionary manufacturing by producing three Tempest B1 drones, repairing a downed Tempest within just 72 hours using 3D printed components, and supporting allied operations with M777 Howitzer traverse assemblies. It also swiftly fulfilled a DEVCOM request by fabricating 10 ground sensor components overnight, highlighting its agility and operational effectiveness.
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Featured image shows ForgeX, Expandable Composite 3D Printing Shelter. Image via SelectTech Services Corporation.
