Read more: In 2021, the US Naval Institute announced a partnership with Xerox and a decision to equip the Navy and Marine Corps with ElemX 3D printers to explore the potential of new applications for 3D printers. Now, this case study of 3D printing in the Navy has taken another step forward.

 

The aircraft carrier USS Essex

13 July 2022 - The US Naval Institute has now partnered with the Commander, Naval Surface Forces, Pacific Fleet (COMNAVSURFPAC) to install 3D printers on US warships, making this the first case of a 3D printer on a ship. According to a COMNAVSURFPAC press release, the Xerox 3D printer will be fitted to the Wasp-class amphibious assault ship, the aircraft carrier USS Essex (LHD 2).

3D printing is becoming increasingly attractive in many industries due to its short production cycle times and cost effectiveness, and navies around the world are choosing the technology for more innovative reasons. It has long been thought that by embarking on a 3D printer, ships could become more self-sufficient, especially if replacement parts could be printed even at sea. It was for this reason that the Navy chose the ElemX printer. Not only because of the partnership, of course, but also because this model is one of the fastest printers on the market, thanks to its unique liquid 3D printing process. It is also capable of printing aluminium parts up to 10x10 inches (approximately 254mm) in size, including common parts such as radiators, housings, fuel adapters, exhaust valves, valve covers and more.

 

△Xerox technician Dan Porter assembles a 3D printed head on the USS Essex. Photo credit: US Navy

While the Essex has always had the capability to make the smaller items needed on board, they hope the 3D printer will expand their manufacturing capabilities. Jonah Waage, Avionics Technician II, added: "We've never been able to make parts as precise and complex as what the new 3D printer offers, which is important because it will help save our Navy time and money in the long run." Ultimately, the Navy's goal is to test and evaluate the 3D printer in underway (at sea) conditions to determine its viability when out at sea, which is their long-term project. the USS Essex is the first ship to be involved, but it seems likely that other ships will join in the future.

USS Essex becomes the first US ship to be equipped with a 3D printer

Additive manufacturing applications in the maritime sector are nothing new, and naval forces seem to be increasingly inclined towards the technology, but this event does mark the first time a US Navy ship has been fitted with a 3D printer at sea. Having said that, 3D printers are not the first time they have appeared on a warship. Notably, in 2019, the French aircraft carrier Charles de Gaulle carried a 3D printer on board. However, this initiative shows how other navies can see the advantages, particularly in terms of the "readiness" of ships that may be far from port. The next step in this particular project will be to train sailors on board the USS Essex to use the equipment.

 

Xerox technicians Dan Porter (left) and Andrew Wong (right), Emergency Ship Salvage Material (ESSM), diagnose the 3D printer on board the USS Essex. Photo credit: US Navy

Nicolas Batista, Aircraft Intermediate Maintenance Division (AIMD) officer on board the Essex aircraft carrier, concluded: "Having this printer will accelerate, enhance and improve our readiness overall. Additive manufacturing (AM) has become an imperative and it is clear that it will provide a greater posture in operational efforts across the fleet and will enhance expeditionary maintenance and contribute to our competitive advantage on the surface."