US shipyard for first time 3D printing parts for new aircraft carriers

The U.S. maritime industry is witnessing a significant transformation as Newport News Shipbuilding (NNS), a division of defense contractor HII, successfully integrates 3D printing into its shipbuilding processes. The shipyard has recently 3D-printed and installed a major valve manifold assembly on the aircraft carrier Enterprise, marking a pivotal step in modernizing ship construction. This innovative approach aims to enhance efficiency and quality in the production of military vessels.

Innovative Manufacturing Techniques at Newport News Shipbuilding

Newport News Shipbuilding has made headlines by 3D-printing a substantial valve manifold assembly measuring five feet long and weighing 1,000 pounds. This component is crucial for distributing fluids throughout the Gerald R. Ford-class aircraft carrier, Enterprise. The shipyard’s announcement highlights the potential of certified 3D-printed parts to accelerate the construction and delivery of both military and merchant vessels. By improving manufacturing quality for essential components, this technology could reshape the future of shipbuilding.

The development of the manifold was a collaborative effort with DM3D Technology, a Michigan-based specialist in 3D metal printing. Following this success, plans are underway to produce similar manifolds for the upcoming carrier Doris Miller (CVN 81) using the same advanced techniques, moving away from traditional casting methods. This shift not only promises to streamline production but also enhances the overall quality of the components being manufactured.

ABS and HD Hyundai Heavy Industries Sign JDP to Advance 3D Printing

The U.S. Army, Navy, and Department of Defense have been exploring 3D printing since 2012, evolving from simple prototyping to the production of parts for various military applications. This technology has proven particularly beneficial for older equipment, where replacement parts are often no longer available. Dave Bolcar, NNS vice president of engineering and design, emphasized the significance of this innovation, stating, “What started as a proof of concept quickly turned into a tangible result that is making a meaningful difference to improve efficiencies in shipbuilding.”

Expanding the Role of Additive Manufacturing

Newport News Shipbuilding has already established itself as a certified supplier of additive manufacturing components for Naval Sea Systems (NAVSEA) platforms. To date, the shipyard has produced over 55 additively manufactured parts for both new vessels and those currently in service. Looking ahead, NNS plans to install more than 200 additional parts this year, further integrating 3D printing into its operations.

This innovative approach not only enhances the shipbuilding process but also positions the U.S. maritime industry to better compete in a challenging global market. As the industry grapples with the need to revive its shipbuilding capacity, advancements like these could play a crucial role in shaping the future of naval construction. The successful implementation of 3D printing at Newport News Shipbuilding serves as a promising example of how technology can drive efficiency and quality in the maritime sector.