The Consortium for Additive Manufacturing Research and Education (CAMRE) at the Naval Postgraduate School (NPS) recently conducted a demonstration of in-flight 3D printing aboard a U.S. Marine Corps MV-22 Osprey tiltrotor aircraft.
This successful test of in-flight additive manufacturing represents a capability which could prove vital for rapid response during any contested logistics scenario.
“We are in a unique position to rapidly support the joint force and accelerate the adoption of advanced manufacturing,” said Chris Curran, program manager at CAMRE. “This is just one of many events we are committing resources to where we share our research and deliver equipment and know-how to servicemembers.”
CAMRE worked in collaboration with the MIU and Marine Aircraft Group (MAG) 39 from Marine Corps Air Station Camp Pendleton, Calif., to set up the demonstration. The flight was conducted with the support of Marines and aircraft from the “Knightriders” of Marine Medium Tiltrotor Squadron (VMM) 164, commanded by Lt. Col. Casey Nelson.
The 3D printer utilized in the demonstration, was developed by Spencer Koroly, an engineer at Naval Information Warfare Center (NIWC) Pacific in San Diego. AMOS – the 3D printer which stands for the Advanced Manufacturing Operational System –, is known for its speed, reliability and expeditionary ruggedness when benchmarked to comparable systems.
The test
During the test, the team began with a 3D scan of a Marine’s arm, which was used to create a drawing of a medical cast assisted by generative design software. The cast itself was then printed while the Osprey was engaged in multiple ground and flight modes, including taxi, takeoff and in-flight maneuvers.
“We are just scratching the surface on the capabilities that will come from being able to 3D print in flight,” said Lt. Col. Michael Radigan, who serves as a liaison to NPS from the MIU. “Dozens of printers being installed in a modular fashion aboard aircraft brings the ability for mobile production at a scale we have not experienced before.”
CAMRE’s airborne 3D printing demonstration builds upon past successful operational demonstrations with the fleet, including the first deployment of a 3D liquid metal printer aboard USS Essex (LHD 2) during the Rim of the Pacific (RIMPAC) exercise in 2022.
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