TheUS Marine Corpshas successfully leveraged additive manufacturing to aid their mine-clearing missions, having 3D printed a headcap for a rocket motor used to detonate an M58 Mine Clearing Line Charge (MICLIC).
The MICLIC is a rocket-projected explosive line charge that clears a path through minefields and other obstacles on the battlefield. 3D printing the headcap enabled the marines to overcome the costly and time-heavy drawbacks of traditional manufacturing techniques, and provide a more efficient method for producing the part.
“The process of 3D printing allows marines to create a physical object from a digital design,” said CWO2 Justin Trejo, a project officer with PM Ammo at Marine Corps Systems Command (MCSC). “We essentially created a 3D printed product and incorporated it into a highly explosive system. The rocket motor fired off just as intended and the line charge detonated as it is supposed to, which was a significant moment for us.
“In the future, we’d like to attempt to 3D print the headcap with its nozzles attached.”
3D printing the headcap
The US Marine Corps has beenchampioning the greater adoption of 3D printingfor several years now, and has continued to explore the technology’s potential to improve processes, parts, lead times, and cost savings.
The organization has previously leveraged the technology to aid the maintenance, repair, and overhaul (MRO) of itsF/A-18 Hornet fighter jets, and has been used toproduce temporary spare parts on missionsby marine expeditionary units. The Marine Corps has also previously partnered with Texas-based construction firmICONto3D print a concrete vehicle hide structurein just 36 hours, with plans to adopt the technology more widely across the US’ Armed Forces to support military operations around the world.
PM Ammo began exploring alternative production techniques for the MICLIC headcap in 2019, after identifying a need for a more efficient method for manufacturing the part. After extensive research, development, and prototyping, the team partnered with the Naval Surface Warfare Center Corona Divsion to produce the 3D printed component.
The headcap was 3D printed in stainless steel before being tested at Yuma Proving Ground in Arizona. During the test event, the 3D printed headcap was fitted to a rocket motor that was used to successfully detonate a mine-clearing line charge. The success of the test confirmed the effectiveness of 3D printing within defense applications, and its potential for streamlining the production process of critical parts in order to save both time and money.
“The previous process of traditional manufacturing is outdated, while 3D printing is a more modern manufacturing technique,” said Caleb Hughes, an engineer at PM Ammo. “I truly believe 3D printing is the next generation of Marine Corps.”
According to Trejo, 3D printing has the potential to increase the Marines’ battlefield efficiency through enabling its warfighters to be “lighter and faster” when supporting various missions.
“We’re able to create equipment parts and other assets for whatever particular mission we’re engaged in,” he added. “This 3D printed headcap represents the Marine Corps going above and beyond to support our Marines.”
Deploying AM for defense
In February, theUS Department of Defense(DoD) released itsfirst-ever additive manufacturing strategyto establish a common vision for the integration of 3D printing within the nation’s defense program. Despite concerns raised by an independent watchdog regarding“unnecessary cybersecurity risks”, the strategy formally lays out how the DoD plans to scale the technology’s deployment across its Armed Forces.
Since then, the adoption of 3D printing across the US defense sector has continued to increase, with projects underway to develop methods for3D printing high-strength alloys,qualifying corrosion-proof materialsfor maritime applications, and3D printing optimized antenna componentsandcontinuous fiber drone wings, among other things.
国防部还与粘结剂喷射3 d普林斯顿ter manufacturerExOneto develop aportable 3D printing factoryto address spare part production in the field, and has commissioned the building of several specialized 3D printers.
TheUS Air Forceturned to MIT spin-outInkbittobuild three 3D printing systemsfor use at its bases in the US, and has also contracted circuit board fabrication specialistBotFactoryto develop a customizedfully-automated desktop electronics 3D printerthat could save millions of dollars each year in procurement costs. Additionally, theApplied Science & Technology Research Organization(ASTRO America) has been tasked with developing anultra-large-format metal 3D printerfor the production of ground vehicles for the US Army.
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Featured image showsCWO2 Justin Trejo displays a 3D printed headcap for a rocket motor used to employ a M58 Mine Clearing Line Charge. Photo via Tonya Smith/US Marine Corps.
