Metal 3D printing in Defence
When a Single Broken Part Jeopardises a Defence Mission
In modern defence operations, success can hinge on a single mechanical component. A failed pump, cracked housing, or worn-out valve can force vehicles or vessels out of action, causing delays, increasing risk, and adding to operational costs.
Yet, these parts are often not readily available in the field. Traditional logistics require them to be shipped from central depots or manufacturers. This can take days, sometimes even weeks. For high-stakes missions, that’s the time defence teams don’t have.
A Costly and Risky Status Quo
Let’s take a real example. During the 2024 multinational naval exercise RIMPAC, the USS Somerset experienced a failure in its desalination system—a crucial component that converts seawater into drinkable water. A stainless-steel part broke unexpectedly.
Under normal procedures, the ship would need to wait 2–6 weeks for the spare part to arrive. In the meantime, it would either need to operate with limited fresh water or return to port, potentially compromising its role in the exercise and incurring over $500,000 in indirect costs.
The situation reflects a common pattern: spare part logistics are vulnerable, expensive, and slow, especially in remote or mobile operations. Whether it’s a naval ship or a desert-based forward operating base, waiting for parts simply isn’t good enough anymore.
Limited Space, Limited Time
While many defence units have invested in mobile workshops, onboard maintenance rooms, and advanced logistics, they’re often still reliant on stored inventory or complex supply chains. A Navy vessel, for instance, typically has 12–20 m² of workshop space and several rooms for spare part storage. Yet no inventory system can predict every failure.
Teams on the ground need more than parts—they need flexibility, independence, and speed.
What If Spare Parts Could Be Created on the Spot?
Now imagine a different outcome.
Instead of waiting weeks for the broken desalination part, the USS Somerset produced a replacement on board within 24 hours. No external shipment. No mission interruption.
How? By using metal additive manufacturing—a compact, easy-to-use system that fits into a mobile workshop and requires only aluminium wire to function.
The system allowed the crew to design, print, and install a fully functional replacement part with minimal infrastructure. And when another component—a diesel generator’s thermostat housing—failed, the same system recreated the part within 5 hours, even without a 3D scanner.
A Tactical Shift: From Defence Logistics to Agility
With this kind of solution, defence teams can:
- Reduce spare part inventory by up to 20%
- Produce custom parts directly in the field
- Eliminate downtime caused by shipping delays
- Maintain operational readiness with minimal infrastructure
- Lighten payloads and reduce storage space requirements
This isn’t about replacing traditional logistics—it’s about enhancing them with deployable metal 3D printing technology designed for the unique needs of defence environments.
What Makes ValCUN’s Molten Metal Deposition (MMD) System Different?
Many metal additive manufacturing systems are too bulky, power-hungry, or hazardous to be used in real-world defence environments. ValCUN’s Minerva system was engineered from the ground up to solve these issues, delivering industrial-grade capabilities in a format built for forward deployment.
Here’s what sets it apart:
- Truly Deployable
Minerva is designed to fit inside small workshops, containers, or naval maintenance rooms. Its low physical footprint allows for easy integration into space-constrained environments—on land or at sea. It even fits through any regular office door. - Safe to Use Anywhere
Unlike powder-based systems, Minerva uses solid aluminium wire as feedstock, eliminating explosive risks and removing the need for ATEX-certified areas. This makes it safer to operate in enclosed spaces or mobile settings. - Minimal Energy Requirements
Minerva runs on low power and a domestic household plug—ideal for generators or mobile power supplies, often used in the field. It doesn’t need industrial-scale infrastructure and electricity provisions to deliver results. The nominal energy consumption is 1,3kW, which is less than a domestic water kettle. - Rapid Deployment and Startup
The system can be powered up and ready to print in less than 15 minutes, not hours. In emergencies, speed matters—and Minerva delivers. - Multi-Material Capability
While purpose-built for aluminium, Minerva’s flexible design also allows it to function as a standard FDM polymer printer, enabling users to prototype or print non-metal parts on the same machine. This dual-material versatility maximises value and adaptability in the field.
In short, ValCUN’s Minerva brings together deployability, safety, efficiency and flexibility, making it the first metal 3D printing solution truly optimised for defence operations.
Conclusion: Operational Readiness in Defence Starts with Autonomy by 3D Printing
If your team operates in high-stakes, unpredictable environments, you need more than spare parts—you need a way to make them.
Deployable metal additive manufacturing by ValCUN provides that capability. It’s not just a tool—it’s a strategic enabler for mission continuity, agility, and success.
