The Naval Postgraduate School’s Consortium for Additive Manufacturing Research and Education (CAMRE) has achieved a groundbreaking milestone in military logistics. In a historic moment, CAMRE successfully demonstrated in-flight 3D printing by producing a medical cast aboard a U.S. Marine Corps MV-22 Osprey tiltrotor aircraft.
Photo: USMC
Taking place during a larger-scale exercise at Marine Corps Air Ground Combat Center Twentynine Palms, CAMRE and the Marine Innovation Unit (MIU) provided invaluable support to forces participating in the integrated training exercise (ITX). This operational demonstration showcased the potential of in-flight additive manufacturing and its ability to facilitate rapid response in contested logistics scenarios.
CAMRE collaborated with the MIU and Marine Aircraft Group (MAG) 39 from Marine Corps Air Station Camp Pendleton to set up the groundbreaking demonstration. The “Knightriders” of Marine Medium Tiltrotor Squadron (VMM) 164, led by Lt. Col. Casey Nelson, provided crucial assistance throughout the flight.
The demonstration relied on the Advanced Manufacturing Operational System (AMOS), a highly regarded printer developed by engineer Spencer Koroly from the Naval Information Warfare Center (NIWC) Pacific in San Diego. AMOS is renowned for its speed, reliability, and expeditionary ruggedness, making it an ideal choice for in-flight additive manufacturing.
Spencer Koroly hailed the achievement as revolutionary, stating, “Being able to print on the move is truly groundbreaking. Printing medical devices and swarm robotics in the back of an aircraft exemplifies the expeditionary nature of this technology.”
The process began with a 3D scan of a Marine’s arm, which served as the basis for generating a digital model of a medical cast using advanced design software. As the Osprey performed various ground and flight maneuvers, including taxi, takeoff, and in-flight operations, the team successfully printed the medical cast.
Lt. Col. Michael Radigan, serving as a liaison to NPS from the MIU, emphasized the immense potential of in-flight 3D printing, stating, “This is just the beginning. The ability to 3D print in flight opens up a world of possibilities. Installing dozens of printers aboard aircraft in a modular fashion enables mobile production at an unprecedented scale.”
The successful demonstration of in-flight 3D printing by CAMRE marks a significant advancement in military manufacturing capabilities. It not only showcases the Naval Postgraduate School’s commitment to cutting-edge research and technology, but also highlights the potential for agile production in critical situations.
CAMRE’s ability to bring together operating forces from Marine Forces Reserve, I Marine Expeditionary Force (MEF), and 3d Marine Aircraft Wing for the integrated training exercise demonstrates the distributed manufacturing model in a contested logistics environment. This successful achievement builds upon CAMRE’s previous operational demonstrations, including the deployment of a 3D liquid metal printer aboard USS Essex (LHD 2) during the Rim of the Pacific (RIMPAC) exercise in 2022.
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