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How 3D Printing Supports Government and Defense Operations  

Additive manufacturing gives government and defense agencies faster, more flexible solutions to address mission-critical challenges, from strengthening military readiness to advancing space, energy, and health care innovation. 

In practical terms, 3D printing provides advantages that traditional manufacturing can’t match, producing high-capability parts on demand that lower cost, accelerate production, and mitigate supply chain risk. The result – military and government organizations achieve their mission objectives with greater speed, efficiency, and confidence. 

U.S. Military Boeing Osprey Aircraft

Why Government and Defense Organizations Rely On 3D Printing

Additive manufacturing for the defense industry and other government organizations has moved beyond pilot projects into practical, everyday use. Agencies are applying it to shorten lead times, reduce supply chain risk, and improve operational efficiency in ways traditional methods cannot match.

As 3D printing in the defense industry expands, military organizations are using it to produce spare parts, tools, and lightweight components directly where they’re needed, whether in depots, in the field, or aboard ships and aircraft. Civilian agencies rely on the same technology to accelerate research, prototype complex designs, and support critical national infrastructure in energy, space, and health care. Because additive  manufacturing is already delivering measurable value in these demanding environments, government and defense leaders can be confident in the technology’s capability to reliably strengthen readiness, and provide efficiency and innovation.

Real-World Examples

Explore the following articles to see how government and defense agencies benefit from additive manufacturing. They highlight the impact of 3D printing in military applications as well as civilian government agencies.

mh-60 seahawk

3D Printed Parts for the MH-60S Seahawk

Working with engineers from the H-60 helicopter Fleet Support Team, the U.S. Navy uses 3D printing to develop antenna mounts for the aircraft’s Full Motion Video system, expanding its operational capabilities.

F-16-airforce

Developing a Lighter Clamp for the F-16

In this Air Force additive manufacturing competition aimed at finding innovative ways to feasibly sustain aging aircraft components, Stratasys P3 DLP technology was chosen as the optimal choice to make replacement hydraulic line clamps for the F-16 aircraft.

F-18 navy jet.

Mitigating Supply Chain Delays for F-18 Support

Engineers from the U.S. Navy’s Fleet Readiness Center Southwest (FRCSW) used a Stratasys F900 to 3D print a non-structural component for an F-18 fighter aircraft that was backordered for months with no specified delivery date.

field deployed military

Keeping Tactical Drones Flying With 3D Printed Parts

3D printed parts help the 173rd Airborne Brigade Hawkeye Platoon maintain field readiness with custom first-person view drones, highlighting how the Army uses additive manufacturing to its benefit.

Orion spacecraft

Exploring Practical and Research Applications of 3D Printing

The U.S. Department of Energy’s Savannah River National Laboratory relies on additive technology to research new manufacturing methods, shore up supply chains, and discover new materials.

mh-60 seahawk

3D Printed Parts for the MH-60S Seahawk

Working with engineers from the H-60 helicopter Fleet Support Team, the U.S. Navy uses 3D printing to develop antenna mounts for the aircraft’s Full Motion Video system, expanding its operational capabilities.

F-16-airforce

Developing a Lighter Clamp for the F-16

In this Air Force additive manufacturing competition aimed at finding innovative ways to feasibly sustain aging aircraft components, Stratasys P3 DLP technology was chosen as the optimal choice to make replacement hydraulic line clamps for the F-16 aircraft.

F-18 navy jet.

Mitigating Supply Chain Delays for F-18 Support

Engineers from the U.S. Navy’s Fleet Readiness Center Southwest (FRCSW) used a Stratasys F900 to 3D print a non-structural component for an F-18 fighter aircraft that was backordered for months with no specified delivery date.

field deployed military

Keeping Tactical Drones Flying With 3D Printed Parts

3D printed parts help the 173rd Airborne Brigade Hawkeye Platoon maintain field readiness with custom first-person view drones, highlighting how the Army uses additive manufacturing to its benefit.

Orion spacecraft

Exploring Practical and Research Applications of 3D Printing

The U.S. Department of Energy’s Savannah River National Laboratory relies on additive technology to research new manufacturing methods, shore up supply chains, and discover new materials.

Government and Military 3D Printing Applications

All Our Applications

U.S. military and government sector 3D printing programs have an established track record of providing value across a wide range of applications, giving federal agencies faster, leaner ways to sustain and advance operations. The fundamental applications that provide significant benefits include:

3D part printed for a Slingshot device

Production Parts

Faster, on-demand production of replacement components for aircraft, ground vehicles, naval vessels, and general equipment extends the service life of critical assets.

Stratasys 3D printed FDM cap

Jigs and Fixtures

3D printing enables faster creation and deployment of lighter and more ergonomic repair tools, field-ready kits, and manufacturing tooling that reduce lead times and improve efficiency.

GrabCAD Print Pro CAD Preview

Rapid Prototyping

The ability to produce what’s needed, when it’s needed, provides flexibility to produce parts quickly and locally instead of waiting on traditional supply chains.

GrabCAD Print Pro projectile design preview

Composite Tooling

With advanced polymers and composites, 3D printed parts can replace heavier metal components, improving fuel efficiency, mobility, and mission agility.

3D part printed for a Slingshot device

Production Parts

Faster, on-demand production of replacement components for aircraft, ground vehicles, naval vessels, and general equipment extends the service life of critical assets.

Stratasys 3D printed FDM cap

Jigs and Fixtures

3D printing enables faster creation and deployment of lighter and more ergonomic repair tools, field-ready kits, and manufacturing tooling that reduce lead times and improve efficiency.

GrabCAD Print Pro CAD Preview

Rapid Prototyping

The ability to produce what’s needed, when it’s needed, provides flexibility to produce parts quickly and locally instead of waiting on traditional supply chains.

GrabCAD Print Pro projectile design preview

Composite Tooling

With advanced polymers and composites, 3D printed parts can replace heavier metal components, improving fuel efficiency, mobility, and mission agility.

Certification, Quality Assurance, and Security

In government and defense programs, additive manufacturing follows a rigorous framework of qualification and certification to ensure parts can be trusted in mission-critical use. These standards are particularly essential for military additive manufacturing, where validated processes, certified materials, and cybersecurity protections ensure every part meets stringent defense and aerospace requirements.

By combining certified processes, validated production, and advanced cybersecurity, Stratasys gives government and defense organizations confidence that every part meets the highest standards of quality and security. 

Stratasys Fortus 900 digital

Proven Compliance

Stratasys additive solutions are built on certified quality management systems including ISO 9001, AS9100, and ISO 13485, with additional FAA and AMS7100 compliance for aerospace.

dental service

Validated Production

Printing services fulfilled through Stratasys Direct contract manufacturing undergo strict testing and include full traceability with Certificates of Conformance to validate quality and specifications throughout production.

Blue lock with a geometric background representing cybersecurity.

Cybersecurity Protection

Cybersecurity for government and DoD additive manufacturing projects is assured by advanced protocols such as CMMC 2.0, NIST 800-171, DFARS, and ITAR. The ProtectAM platform on the F900 printer provides STIG-compliant security across distributed defense networks for sensitive design and manufacturing data.

Stratasys Fortus 900 digital

Stratasys additive solutions are built on certified quality management systems including ISO 9001, AS9100, and ISO 13485, with additional FAA and AMS7100 compliance for aerospace.

dental service

Printing services fulfilled through Stratasys Direct contract manufacturing undergo strict testing and include full traceability with Certificates of Conformance to validate quality and specifications throughout production.

Blue lock with a geometric background representing cybersecurity.

Cybersecurity for government and DoD additive manufacturing projects is assured by advanced protocols such as CMMC 2.0, NIST 800-171, DFARS, and ITAR. The ProtectAM platform on the F900 printer provides STIG-compliant security across distributed defense networks for sensitive design and manufacturing data.

3D Printers for Government and Defense

All Printers

Government and defense organizations require a range of additive solutions, from rugged field printers that support deployed forces to advanced systems used in research labs and production facilities.

Stratasys printers, spanning multiple 3D printing technologies and powered by a comprehensive software ecosystem, are built to meet these diverse needs, supporting everything from point-of-need part production to large-scale manufacturing programs.

F170 with part

F170 FDM Printer

Compact, dependable, entry-level professional-grade printer for accurate, repeatable 3D printing. Form factor and ease of use make it suitable for the classroom or office.

F370 with part

F370 FDM 3D Printer

Accessible, industrial-grade 3D printer. Combines fast and easy material swaps, a generous build volume, and dependable print results to provide accurate, repeatable prototypes to production parts. Suitable for the office or factory floor.

F190CR front lit up

F190CR FDM Printer

A compact printer compatible with carbon fiber and engineering-grade thermoplastics to produce strong prototypes, jigs and fixtures, tooling, and parts from the classroom to the office to the factory floor.

F370CR - Stratasys F123 Series Composite-Ready 3D Printer

F370CR FDM Printer

A professional, industrial-grade printer compatible with carbon fiber and engineering-grade thermoplastics to produce functional prototypes, strong workholding fixtures, tooling, and parts in the office or classroom.

Stratasys F770 FDM 3D Printer

FDM F770 3D Printer

The F770 FDM 3D printer offers one of the largest print volumes among Stratasys FDM systems. With over 13 cubic feet of build volume and the widest build chamber (X direction) of any Stratasys FDM 3D printer, the F770 can build large parts or sizable assortments of smaller parts.

fortus-450-mc

Fortus 450mc 3D Printer

Designed for customers who demand durability, precision, and repeatability, the Fortus 450mc printer has proven its value across aerospace, automotive, and general industrial sectors.

Stratasys F900 FDM 3D Printer

F900 Industrial 3D Printer

Produce highly accurate 3D printed parts, with repeatability, and reliable performance from the best industrial FDM 3D printer on the market. A favorite within Aerospace, Automotive, and Industrial Manufacturing.

Stratasys Origin Two Door Open P3 DLP Printer

Origin® Two 3D Printer

Origin® Two brings industrial 3D printing to a completely new level with unparalleled accuracy, proven repeatability, very tight tolerances, and superb smooth surface finish.

F170 with part

F170 FDM Printer

Compact, dependable, entry-level professional-grade printer for accurate, repeatable 3D printing. Form factor and ease of use make it suitable for the classroom or office.

F370 with part

F370 FDM 3D Printer

Accessible, industrial-grade 3D printer. Combines fast and easy material swaps, a generous build volume, and dependable print results to provide accurate, repeatable prototypes to production parts. Suitable for the office or factory floor.

F190CR front lit up

F190CR FDM Printer

A compact printer compatible with carbon fiber and engineering-grade thermoplastics to produce strong prototypes, jigs and fixtures, tooling, and parts from the classroom to the office to the factory floor.

F370CR - Stratasys F123 Series Composite-Ready 3D Printer

F370CR FDM Printer

A professional, industrial-grade printer compatible with carbon fiber and engineering-grade thermoplastics to produce functional prototypes, strong workholding fixtures, tooling, and parts in the office or classroom.

Stratasys F770 FDM 3D Printer

FDM F770 3D Printer

The F770 FDM 3D printer offers one of the largest print volumes among Stratasys FDM systems. With over 13 cubic feet of build volume and the widest build chamber (X direction) of any Stratasys FDM 3D printer, the F770 can build large parts or sizable assortments of smaller parts.

fortus-450-mc

Fortus 450mc 3D Printer

Designed for customers who demand durability, precision, and repeatability, the Fortus 450mc printer has proven its value across aerospace, automotive, and general industrial sectors.

Stratasys F900 FDM 3D Printer

F900 Industrial 3D Printer

Produce highly accurate 3D printed parts, with repeatability, and reliable performance from the best industrial FDM 3D printer on the market. A favorite within Aerospace, Automotive, and Industrial Manufacturing.

Stratasys Origin Two Door Open P3 DLP Printer

Origin® Two 3D Printer

Origin® Two brings industrial 3D printing to a completely new level with unparalleled accuracy, proven repeatability, very tight tolerances, and superb smooth surface finish.

Reshape your drone manufacturing

Leverage the power of additive manufacturing for efficient production of high-performance drones and drone components.

3D Printing Materials for Government and Defense

All Materials

The demands of government and defense applications often require materials that can withstand extreme environments while maintaining strength, reliability, and safety. Stratasys provides a broad portfolio of military-grade 3D printing materials proven in aerospace and defense, energy, and other government applications. Combined with advanced Stratasys 3D printers, this broad portfolio of capable materials gives government and defense organizations the ability to produce reliable, certifiable parts for applications ranging from military vehicles and aircraft to space systems, research, and health care.

abs m30 part2

Production Parts

These materials exhibit strong mechanical and thermal performance and include thermoplastics like ABS and ASA, industrial nylon, and industrial-grade photopolymer resins.

loctite 3955 FST material | Stratasys Direct

Specialty Materials for Unique Conditions

Formulated for specific requirements, these materials employ capabilities such as elastomeric properties, flame retardancy (FR), flame, smoke, and toxicity (FST) compliance, and electrostatic-dissipative (ESD) properties.

3D printing components like this oil and gas backup ring with Kepstan PEKK-SC avoids the waste associated with machining them from stock PEKK and PEEK materials.

High-Performance Materials for Extreme Environments

These materials are built for more demanding conditions, designed to resist high heat, chemicals, and mechanical loads. This category includes high-end thermoplastics like polyetherketoneketone (PEKK), polyetheretherketone (PEEK), and polyetherimide (PEI) as well as carbon fiber materials.

abs m30 part2

These materials exhibit strong mechanical and thermal performance and include thermoplastics like ABS and ASA, industrial nylon, and industrial-grade photopolymer resins.

loctite 3955 FST material | Stratasys Direct

Formulated for specific requirements, these materials employ capabilities such as elastomeric properties, flame retardancy (FR), flame, smoke, and toxicity (FST) compliance, and electrostatic-dissipative (ESD) properties.

3D printing components like this oil and gas backup ring with Kepstan PEKK-SC avoids the waste associated with machining them from stock PEKK and PEEK materials.

These materials are built for more demanding conditions, designed to resist high heat, chemicals, and mechanical loads. This category includes high-end thermoplastics like polyetherketoneketone (PEKK), polyetheretherketone (PEEK), and polyetherimide (PEI) as well as carbon fiber materials.

FAQ

3D printing gives government and defense organizations faster, more flexible ways to keep mission-critical systems operational. By producing parts on demand, defense organizations reduce reliance on supply chains, lower maintenance costs, and improve readiness in the field. Beyond defense-specific applications, additive technology helps government agencies shorten design cycles, reduce tooling costs, extend the life of legacy platforms, and enable more agile production of low-volume, specialized components that would otherwise be cost-prohibitive.

NASA applies additive manufacturing for rocket engines, satellites, and habitat concepts. The Department of Energy uses it to accelerate nuclear research and energy infrastructure projects, while government health care agencies use 3D printing for medical models, prosthetics, and training tools.

Additive manufacturing enables rapid prototyping and testing of new designs, from aerospace systems at NASA to next-generation energy solutions at Department of Energy labs. This accelerates discovery while reducing the cost of experimentation.

Yes. Agencies reduce expenses by replacing physical inventory with digital part files, prototyping equipment faster, and producing parts on demand rather than relying on long procurement cycles. In short, additive manufacturing provides efficient solutions that can be applied to many different applications across the range of government and defense agencies.

Military applications of 3D printing include spare parts for aircraft, ground vehicles, naval vessels, lightweight UAV structures, custom tools and fixtures, and protective equipment. Additive manufacturing supports every branch of the U.S. military with faster, mission-specific solutions.

Yes, there are numerous materials that meet stringent military and aerospace standards such as flame, smoke, toxicity, and outgassing requirements. Rigorous testing and certification ensure 3D printed parts can be trusted in mission-critical applications.

  Military-grade 3D printing materials include high-performance thermoplastics (ULTEM™ resins, Antero PEKK, Nylon 12CF carbon fiber) for strength and durability, flame-retardant polymers for safety, and elastomers for impact resistance. These materials provide the balance of strength, lightweighting, and reliability needed across land, sea, air, and space platforms.  

Additive manufacturing reduces reliance on vulnerable supply lines by enabling part production closer to where they are needed. Secure digital part files can be transmitted and printed in-theater, minimizing transport risks and improving operational resilience.

Yes. By lowering tooling expenses, reducing spare-parts inventory, and enabling on-demand production, additive manufacturing can cut lifecycle costs significantly. For the defense industry, this means more budget flexibility for modernization while sustaining legacy fleets.  

Future trends include continued scaling up of defense-related 3D printing programs, expanding field-deployable systems across the Army and Marines, and increasing the use of certified, high-performance materials for aircraft and spacecraft. As military 3D printing matures, expect broader adoption of production parts and integration into digital logistics networks.