Charles R. Goulding and Preeti Sulibhavi explore how the U.S. Navy is leveraging 3D printing to modernize its submarine fleet, revamp the maritime industrial base, and drive innovation in defense manufacturing.
The U.S. Navy is actively integrating 3D printing to enhance its submarine fleet and revitalize the nation’s maritime industrial base. This initiative aims to expedite production, streamline maintenance, and address the challenges posed by an aging industrial defense infrastructure.
The Imperative for Modernization
At the 2025 Additive Manufacturing (AM) Conference in New York, Mathew Sermon, Executive Director of the Program Executive Office for Strategic Submarines (PEO-SSBN), emphasized the critical need for a comprehensive overhaul of the U.S. maritime industry. He likened the required effort to a “Manhattan Project,” underscoring the magnitude of the task ahead. Sermon highlighted the potential of 3D printing to revolutionize ship and submarine construction, envisioning a future where entire hull sections could be produced using additive manufacturing techniques.
Rear Admiral Jonathan Rucker, Program Executive Officer for Attack Submarines (PEO-SSN), echoed this sentiment during the Naval Submarine League conference. He described the current industrial base as “exceptionally fragile” and called upon industry partners to adopt 3D printing to accelerate the production and maintenance of submarine components. “We need your help. We don’t have a choice. Time is not on our side,” Rucker stated, emphasizing the urgency of the situation.
Advancements in Additive Manufacturing
The Navy has already begun integrating 3D printed components into its submarines. In 2024, eight metal parts produced through additive manufacturing were installed on submarines, a notable increase from just two the previous year. Looking ahead, the USS Michigan’s overhaul in 2025 is slated to include thirty-three 3D printed components. Vice Admiral Robert Gaucher, commander of Naval Submarine Forces, noted that delivering these parts via 3D printing is faster than traditional casting methods, helping to mitigate supply chain delays.
One significant achievement in this realm is the production of a 3,300-pound metal part using 3D printing. This component is currently undergoing rigorous testing to ensure it meets the Navy’s stringent standards. Such advancements demonstrate the potential of additive manufacturing to produce high-quality parts more efficiently than traditional methods, which often require extensive machining to address imperfections.
Collaborative Efforts and Future Aspirations
The Navy is not pursuing this transformation in isolation. It is actively seeking collaboration with both domestic and international partners to foster innovation in 3D printing. The AUKUS alliance, comprising the U.S., Australia, and the United Kingdom, plays a pivotal role in this endeavor. Sermon emphasized the importance of leveraging a modern industrial base, stating, “We absolutely want their industrial base [using] a 2030s model… not a 1970s industrial base.”
Australian additive manufacturing firm AML3D has already joined the Navy’s research initiatives, contributing to the development of 3D printed components for submarines. Rear Admiral Rucker confirmed progress in this collaboration, with engineering drawings advancing toward approval.
Challenges and the Path Forward
Despite these advancements, significant challenges remain. The post-Cold War decline in submarine production has left the industrial base at less than half its former size. Admiral Bill Houston, director of the Navy Nuclear Propulsion Program, described the current state as a race to catch up after years of neglect. However, recent achievements, such as increasing the number of qualified casting vendors and integrating 3D printing into production, signal progress. Rucker noted that casting bottlenecks, once a significant issue, have largely been resolved with contributions from international partners.
The integration of additive manufacturing is poised to further enhance the Navy’s capabilities, enabling faster production and maintenance of critical components. As the Navy continues to collaborate with industry partners and allies, the vision of a revitalized maritime industrial base, equipped with cutting-edge 3D printing technology, moves closer to reality.
The Research & Development Tax Credit
The now permanent Research and Development (R&D) Tax Credit is available for companies developing new or improved products, processes and/or software.
3D printing can help boost a company’s R&D Tax Credits. Wages for technical employees creating, testing and revising 3D printed prototypes are typically eligible expenses toward the R&D Tax Credit. Similarly, when used as a method of improving a process, time spent integrating 3D printing hardware and software can also be an eligible R&D expense. Lastly, when used for modeling and preproduction, the costs of filaments consumed during the development process may also be recovered.
Whether it is used for creating and testing prototypes or for final production, 3D printing is a great indicator that R&D Credit-eligible activities are taking place. Companies implementing this technology at any point should consider taking advantage of R&D Tax Credits.
Conclusion
The U.S. Navy’s commitment to adopting additive manufacturing represents a transformative approach to modernizing its submarine fleet and strengthening the broader maritime industrial base. Through strategic collaborations and technological innovation, the Navy aims to overcome current challenges and build a more resilient and advanced naval force for the future.
