SPEE3D’s cold spray metal additive manufacturing recently helped manufacture mission-critical parts at sea and ashore. The work spanned a distributed network linking ships and shore-based facilities.
The teams produced these parts during RIMPAC 2026, the world’s largest international maritime exercise.
The US joint-branch effort brings together several organisations. They include the Consortium for Advanced Manufacturing Research and Education (CAMRE) at the Naval Postgraduate School (NPS). The US Army Combat Capability Development Command Army Research Laboratory (ARL) serves as its government lead. Other participants include the Tennessee Army National Guard and the University of Tennessee Knoxville (UTK) Defense Development and Applied Research Center (DARC).
The deployment of all manufacturing technologies onsite took place through a Partnership Intermediary Agreement with FLEETWERX. This innovation hub brings together experts from government, industry, and academia.
“Producing parts at sea on NATO vessels using coalition equipment is an example of the flexibility and interoperability that are key to modern operations,” said Morgan Bower, FLEETWERX Hub Director. “RIMPAC offers a unique opportunity to bring innovative advanced manufacturing capabilities out of the lab and test them in a realistic maritime environment.”
The exercise conducted with cold spray metal AM
The exercise deployed more than 50 advanced manufacturing technologies. Among them, SPEE3D cold spray systems printed 32 mission-critical metal parts.
The Knoxville Armory’s global reach back capability produced 24 parts. Meanwhile, SPEE3D’s EMU system printed eight at sea aboard the MV Asterix. Teams fully completed 29 of the 32 parts, including heat treatment and machining.
How the system supports production at sea
SPEE3D’s Cold Spray AM deposits metal powder at supersonic speed. It builds dense metal parts without melting the powder. The rugged, compact system can therefore operate in the field and at sea.
The EMU pairs a containerized XSPEE3D metal 3D printer with an integrated SPEE3Dcell post-processing and machining unit. As a result, a part can go from printing to completion without leaving the ship.
“At RIMPAC 2026 we deployed our Expeditionary Manufacturing Unit at sea for the first time, printing mission-critical metal parts on an open deck in heavy seas aboard the MV Asterix, alongside the US Navy and the Royal Canadian Navy. That is what it means to bring production to the fight. Across our deployments, we have now proven Cold Spray Manufacturing in sub-zero, tropical, battle-damage and at-sea conditions, the proof that SPEE3D works where supply chains fail. We’re proud to have supported our partners in putting this to the test in one of the most demanding environments there is,” said Byron Kennedy, CEO of SPEE3D.
The scale of RIMPAC 2026
RIMPAC 2026 was the exercise’s 30th iteration. It ran in and around the Hawaiian Islands and brought together dozens of allied and partner nations. In total, participants included 40 surface ships, five submarines, 140 aircraft, and more than 25,000 personnel.
All images: SPEE3D.
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