Australian Army advances metal 3D printing through latest field test

China3D printingOn November 2nd, the Australian Army conducted the latest field test using metal 3D printing technology developed by SPEE3D.
Following the success of several 3D printing trials last year, the latest test was carried out as part of the annual military exercise Koolendong of the rotating forces of the Australian Army and Marine Corps. The field test was conducted in the remote jungles of the Northern Territory and involved the use of the company’s WarpSPEE3D Tactile 3D printer for 3D printing and the replacement of many spare parts for the M113 armored personnel carrier.

According to SPEE3D, this is one of the most difficult ordeals of the system so far, having been tested for three weeks under extremely high temperature and dusty conditions. WarpSPEE3D also transported more than 1,200 kilometers on rugged terrain to test its robustness on site.
SPEE3D CEO Byron Kennedy said: “This is a good example of how expeditionary metal 3D printing can improve defense preparedness. Field trials conducted in 2020 proved that SPEE3D technology is deployable. This year’s trial postponement is larger and more extensive. Longer and farther, making it the most difficult and longest metal 3D printing experiment in the world to date.”


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On SPEE3D WarpSPEE3D3D printingReplacement of exhaust pipe parts. The photo is from SPEE3D.

SPEE3D’s cold spray3D printingtechnology

SPEE3D focuses on cold spray technology, which is a form of 3D printing that involves spraying metal powder onto a substrate at high speed. The process does not rely on lasers or any other heat-based energy sources, but uses the power of kinetic energy.
Especially WarpSPEE3D, which uses compressed air to spray metal powder to make the raw material have enough speed to deform and fuse with the substrate upon impact. It can print large metal parts up to 40 kg with a fast print quality of up to 100 g/min.

For some time, the Australian Army has been trying to integrate additive manufacturing into its maintenance work, with the original plan and strategy going back to 2014. Due to its Australian background, SPEE3D was finally selected to cooperate with the Australian Army and the Royal Australian Navy to make the Australian Defense Force’s on-demand 3D printing possible.
According to China3D printingThe network understands that the 2020 trial is the world’s first in testing the feasibility of metal 3D printing in military camps and on-site. They were extended to 2021 to verify the initial successful results.



Australian Army Corporal Sean Barton (right) and artisan Naythan Ryan from the 1st Combat Service Support Battalion are deploying WarpSPEE 3D printers. The photo is from the Australian Army.

Field test in 2021

This year, SPEE3D has been dedicated to helping train the Australian Army’s first batch of military additive manufacturing cell (AMC) technicians. The plan aims to cultivate a workforce specializing in the design, printing, processing, heat treatment and certification of on-site metal 3D printed parts.
As part of the latest experiment, the task of AMC technicians is to produce several different replacement parts for the M113 armored personnel carrier. This includes an exhaust pipe and a 2 kg wheel bearing cover-this component is often severely damaged due to rough terrain and trees. The team was able to 3D print the replacement cover in just 29 minutes for less than $100 and integrate it into the vehicle after successfully passing the certification process.
The Australian Army now intends to explore 3D printing, upgrade and repair more field-ready components, aiming to take defense preparedness to new heights.

3D printed wheel bearing caps mounted on M113. The photo is from SPEE3D.

However, the defense application of additive manufacturing is not just about vehicle maintenance. More and more advanced projects are being launched around the world. The U.S. Marine Corps recently used 3D printing to assist in their minesweeping missions, printing the top cover for the rocket engine used to detonate the M58 mine-sweeping line charge (MICLIC). The 3D printed headgear allows the Marine Corps to overcome the disadvantages of traditional manufacturing techniques that are expensive and time-efficient.

Elsewhere, software developer General Lattice recently signed a contract with the US Army to use 3D printing and advanced lattice geometry to improve the impact absorption capabilities of Army combat helmets. The R&D project is currently underway, and the company will develop a predictive modeling tool set to design and generate high-performance lattice structures for helmets.

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