The U.S. defense industry is entering a period of significant growth. The National Defense Authorization Act (NDAA) is estimated at $961 billion between the Department of War and the Department of Energy. The potential for conflict in the Indo-Pacific region has shifted the scope of equipment utilized in these environments, creating a need for higher investment. Demand for new and modernized vehicle systems is increasing across all branches of the military, from the Army and the Navy to the Air Force and the new Space Force. This is especially relevant in light of the rising use of drones and unmanned autonomous systems.
Additive manufacturing (AM) is closely aligned with this growth. The U.S. Department of War’s FY 2026 budget request allocates $3.3 billion for AM-related projects, an 83% increase from the previous year. These dollars are intended to support two major priorities: new product development and the sustainment of legacy vehicles and equipment.
The Strategic Value of AM
Industrial 3D printing has evolved into a critical asset for defense because it directly addresses needs that traditional manufacturing can no longer meet at pace and at scale. The NDAA identifies several priority areas where AM can have an immediate impact, beginning with the sustainment of the hundreds of thousands of vehicles currently in service. In many cases, traditional product contracts are seriously delinquent, prompting sustainment acquisitions agencies to issue AM contracts to produce quick, limited-use components that keep systems operational in the field. At the same time, the military is turning to industrial 3D printing to support new product categories where surge manufacturing is essential, including munitions, drones, and counter-drones.
With increasing demand for AM sources of supply able to meet defense requirements, the industrial base is meeting it through several approaches, such as contract manufacturing and vertical integration. Several key suppliers have recently announced significant investments in capital equipment to expand their additive manufacturing capabilities and build end-to-end production solutions. AM’s growing role in sustainment and end-to-end component development — along with its ability to accelerate the production of castings and forgings — illustrates why it has become such an important resource for defense manufacturing. It enables the speed, flexibility, and responsiveness that the industrial base relies on.
The Pressures Limiting Progress
Despite strong momentum toward greater adoption of industrial 3D printing, barriers remain. Qualification continues to be one of the steepest hurdles. The defense industry has rigorous standards for performance, safety, and repeatability. For AM to scale meaningfully, the sector must establish consistent qualification pathways to meet these standards. Otherwise, we risk slowing the deployment of urgently needed technologies.
Supply chain constraints add an additional layer of complexity. The push for greater saturation of U.S.-made products is limited by mineral access and manufacturing capacity. The talent shortage is a major factor behind these capacity challenges. The defense industrial base is already facing workforce pressures, and some traditional suppliers are still building their AM capabilities. While certifications required for defense manufacturing are often the same as those used within the transportation supply base, many traditional defense suppliers still need to invest time and money in getting their companies certified. As such, training, education, and workforce development are vital components of national readiness. Organizations like SME play an important role here by offering advanced manufacturing training that aligns with the realities of defense production.
Another priority emerging across the industrial base is the need for online model access. To enable suppliers to produce parts, original equipment manufacturers (OEMs) will have to develop “pay for access” platforms for component-level product models. Without this, Tier 1 and 2 suppliers will be unable to respond with the agility that the Department of War requires, exacerbating sustainment backlogs.
Mission Critical Manufacturing
Within the defense industrial base, innovation, speed to market, and reducing the acquisition process are all top priorities. These objectives have not historically been aligned with the dynamics of the defense marketplace. As a result, many traditional suppliers are seeking out non-traditional partners, and some non-traditional suppliers are now engaging directly with the Department of War. Real-world examples highlight just how quickly this market is growing. The Space Force is leveraging AM for critical hardware. Velo3D attributes much of its recent multi-million-dollar growth to contracts from the space and defense sectors. JuggerBot 3D was recently awarded $4 million by the Air Force Research Laboratory (AFRL) to create a large-scale hybrid additive system, and 3D Systems received a $7.65 million contract from the Air Force to support the development of metal AM capabilities for high-speed flight applications.
Meanwhile, the Navy has demonstrated the use of 3D printing to replace failed components at sea in a matter of hours, restoring mission capability without returning to port. The Air Force and Marine Corps brought a grounded F-15 Eagle back into operation months ahead of schedule, using AM to print and replace a cockpit cooling duct. And the Army is testing portable 3D-printing labs in Hawaii that allow soldiers to design, print, and assemble FPV drones on site within hours. AM is becoming a key enabler of production and sustainment, not just a tool for R&D.
Co-produced by SME and the TCT Group, RAPID + TCT supports continued innovation in how additive technologies are implemented within the defense sector. The AeroDef Manufacturing Showcase at RAPID + TCT 2026 will bring together leaders in defense and aerospace equipment, material development, and end-to-end production. Attendees will find resources for building out a full-plant footprint, along with tailored experiences for Department of War advanced manufacturing teams and primes responsible for new product design, including exhibits by the aforementioned Velo3D and JuggerBot 3D. Meanwhile, a dedicated defense conference track, curated by the AeroDef Conference Advisors, will feature perspectives from federal stakeholders, primes, and innovators in the defense manufacturing ecosystem.
The future of defense manufacturing reflects a shared opportunity for both the industrial base and the additive community. Demand for additive solutions is rising, technologies are becoming more sophisticated by the day, and expectations for speed and precision are intensifying. Now more than ever, industrial 3D printing is uniquely positioned to close gaps in production capacity. Through events like RAPID + TCT, SME is equipping the industrial base with the tools to adopt additive technologies effectively and at scale — fortifying the manufacturing systems our nation depends on.
Stacey Eeman is Director of Industry Strategy at SME. RAPID + TCT 2026 will take place from April 13 to 16 at the Thomas M. Menino Convention & Exhibition Center in Boston.