In the aerospace and defense industries, innovation is not just a strategic advantage. It’s a fundamental necessity. Rising geopolitical tensions have placed the need to fortify defense manufacturing systems into stark relief. Traditional procurement cycles are notoriously long. To stay ahead, defense manufacturers need faster, more agile production methods — ones that can adapt quickly to emerging threats without compromising quality or performance.
At Nikon SLM Solutions, we’re seeing firsthand the role additive manufacturing (AM) can play in this evolution. From decentralizing production and enabling rapid, on-demand manufacturing to streamlining complex supply chains and enabling more advanced weapons systems, industrial 3D printing is bolstering efficiency and resilience. Aerospace and defense manufacturers are leveraging the technology to reduce lead times, eliminate bottlenecks, and improve operational readiness in high-stakes environments, making sure critical components are available when and where they are needed most.
Realizing a Tactical Advantage
Traditionally, aerospace and defense manufacturing systems have relied on long design cycles, expensive tooling, and labor-intensive processes. Producing a single component might depend on multiple steps such as casting, forging, machining, or welding — each adding time, cost, and potential points of failure.
Additive Manufacturing flips that paradigm. With advanced metal AM processes like laser powder bed fusion (LPBF), complicated parts that once required multiple components and assemblies can now be produced as a single, optimized structure. AM can also mean improved performance, shorter production cycles, and reduced weight. In an industry where every kilogram of material saved can enhance efficiency and extend range, this is a significant advantage.
That said, AM isn’t for everything. Its strength lies in low- to medium-volume production of highly complex, high-performance parts — exactly what aerospace and defense applications demand. That’s why, within these industries, there is such a focus on metal additive technologies. Every new major weapons system assumes industrial 3D printing as a core manufacturing method, as do advanced spacecraft and aviation platforms. As these sectors push the boundaries of where technology can take us, AM is ensuring we have the tools to get there.
Advancing Marine Manufacturing
One area where this need is especially pronounced is enhancing and strengthening marine deterrents for the U.S. and its allies. The Department of Defense has publicly stressed the need to expand its nuclear-powered submarine fleet. While there has been a concerted effort to hire skilled technicians in areas such as welding and forging, the industrial base faces serious challenges in scaling production. Traditional fabrication processes are time and labor-intensive, limiting the ability to meet demand. In other words, they can only take us so far.
In some cases, AM presents a faster, more efficient route. When deployed appropriately, it can reduce lead times and bolster performance, even in demanding marine environments. A prime example is ST Engineering’s (STE) recent collaboration with Nikon SLM Solutions to redesign and optimize the closed impeller, a critical component in marine propulsion systems. This part presented unique challenges. It required a highly complex geometric design while also needing to withstand harsh, corrosive environments. Conventional modes of production required lead times of up to a year — a problem further compounded by obsolescence issues.
To overcome these barriers, STE leveraged our SLM®500 system in combination with innovative materials like Aheadd® CP1. The approach yielded transformative results: enhanced corrosion resistance, improved durability, and refined component geometry that reduced reliance on support structures. Perhaps most notably, it cut production times by over 90%, allowing for a steady supply of vital parts.
From Potential to Production: AM at Scale
I’ve worked in the AM industry for more than 30 years, witnessing its evolution from a niche technology to a cornerstone of modern manufacturing. Throughout that time, I’ve made attending RAPID + TCT a priority. Unlike broader manufacturing trade shows, RAPID + TCT focuses exclusively on additive technologies, making it a must-attend event for those looking to explore real-world applications of industrial 3D printing.
This year, our team at Nikon SLM Solutions will focus on showcasing how our customers are leveraging our technologies to scale AM for production. The conversation is shifting from “what AM could do” to “what AM is doing today.” Companies are moving beyond prototyping and small-batch experiments — and the implications for industry are massive. With RAPID + TCT 2025 co-located alongside SME’s AeroDef, SAE’s WCX, and America Makes TRX, this year’s event is uniquely positioned to highlight industrial 3D printing’s growing role in critical sectors — like aerospace, defense, and automotive — that fuel the domestic manufacturing economy.
The next phase of AM in aerospace and defense manufacturing won’t just be about making parts — it will be about rethinking how we design, produce, and sustain entire fleets of weapon systems. As AM matures, it’s allowing manufacturers to break free of long-standing time, design, and operational constraints, unlocking new efficiencies in production.
AM is no longer a theoretical innovation. It’s real, it’s proven, and it’s transforming the way we build for the future.
Brent Stucker, Ph.D., is the Chief Engineer for North America for Nikon SLM Solutions. In this role, Brent works within the engineering organization to help keep the company at the forefront of additive manufacturing technological advancement. Nikon SLM Solutions will exhibit at Booth 3008 at RAPID + TCT 2025.