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Thanks to a >10x improvement in cost productivity over the last decade, additive manufacturing (3D printing) has become the more affordable option for complex metal structures in aerospace and defense for production runs up to 10,000 units per year.
Divergent created a product-agnostic manufacturing system where factories can adaptively switch between vastly different products, like a car chassis or a missile airframe, using the same vertically integrated hardware. This creates a flexible, scalable industrial platform.
Divergent's powder bed fusion technique for metal 3D printing involves laser-welding thousands of distinct layers. This process generates immense data, capturing information at every single layer of a part's creation. This allows for unparalleled in-process monitoring and quality control, creating a highly detailed digital twin for every component manufactured.
A critical challenge for the military is maintaining aging equipment when original suppliers no longer exist. Advanced, flexible factories can reverse-engineer and produce these 'obsolete parts' on demand, solving a critical maintenance bottleneck for in-service submarines and other legacy systems.
While designed to build drones at the point of need, Firestorm's containerized 3D-printing factory is proving invaluable for manufacturing basic repair parts for other military hardware. It can print a replacement for a simple part like a coolant tank that otherwise has a 10-month supply chain lead time.
Modern factories like Hadrian's use software not just for automation but for agility. This allows them to quickly reconfigure production lines for small batches of highly varied parts ('high mix, low volume'), a necessity for complex systems like submarines where components are not mass-produced.
The US defense industry's error was creating a separate, "exquisite" industrial base. The solution is designing weapons that can be built using existing, scalable commercial manufacturing techniques, mirroring the successful approach used during World War II.
The Pentagon is moving away from decades-long, multi-billion dollar projects like aircraft carriers. The new focus is on mass-produced, attributable, low-cost systems like drones, which allows for faster innovation and deployment from new defense tech startups, not just the old primes.
Additive manufacturing enables a new paradigm for military supply chains. Small plastic and metal 3D printers can be placed in standard shipping containers (CONEX boxes) near the front lines, allowing for on-demand production of drones and munitions, increasing responsiveness.
The DoD's critical tech priorities, like hypersonics and directed energy, focus on scaling. The goal is to transform expensive, "exquisite" systems into cheaper, mass-producible assets, shifting the cost-benefit analysis of modern warfare.
Anduril prototypes drone frames by milling them from solid metal blocks. While extremely wasteful and expensive for mass production, this method bypasses the slow and costly process of creating molds for casting, drastically reducing latency during the critical iterative design phase and getting products to market faster.