[ Additive Manufacturing ] synchronising motion between the print head and the substrate to simulate shipboard movement. GKN’ s additive manufacturing platform includes advanced controls that coordinate both elements during printing.“ We approached this challenge by combining our understanding of additive materials behaviour with practical experience in manufacturing process control,” said David Bond, head of Engineering and Technology at GKN Aerospace.“ That integration has been key to developing a solution that can print quality representative samples under the motion conditions expected in shipboard environments.”
[ Additive Manufacturing ] synchronising motion between the print head and the substrate to simulate shipboard movement. GKN’ s additive manufacturing platform includes advanced controls that coordinate both elements during printing.“ We approached this challenge by combining our understanding of additive materials behaviour with practical experience in manufacturing process control,” said David Bond, head of Engineering and Technology at GKN Aerospace.“ That integration has been key to developing a solution that can print quality representative samples under the motion conditions expected in shipboard environments.”
Watch a video of the shipboard motion simulator for additive manufacturing.
Controlled test prints To evaluate the system’ s performance, the team has conducted controlled test prints using triple line trace patterns on metal coupons. They printed sixinch test blocks under different motion profiles analogous to ship motion in calm and rough sea states to study how dynamic conditions affect the quality of the deposited material and, ultimately, to better understand how motion affects the ability to ensure repeatable, structurally sound parts.“ This effort is giving us the data we need to move from concept to capability,” said Bianca Sciandra, the project manager and a metallic materials researcher at APL.“ We’ re now able to quantify how motion influences build integrity and use that insight to refine system controls, bringing us closer to producing critical, mission-relevant parts directly aboard ships.”
A float AM program The work builds on APL’ s contributions to NAVSEA’ s Afloat Additive Manufacturing Program. In 2023, the Lab supported the installation of the Navy’ s first hybrid metal 3D printer aboard a ship, the USS Bataan( LHD 5), and then guided sailors through production of a replacement part at sea.“ The USS Bataan deployment proved that additive manufacturing can work at sea,” said Michael Presley, APL additive manufacturing engineer and lead on the Navy collaboration.“ Now, we’ re taking the next step, shifting from noncritical parts to
mission-essential components like valve housings and structural mounts. This capability enhances the fleet’ s ability to maintain readiness and adapt in real time, even in challenging environments.” APL has also played a central role in the Navy’ s adoption of metal additive manufacturing, demonstrating that precise process control can deliver consistent, high-quality materials for demanding naval applications. Through all of these efforts, the Laboratory aims to further validate onboard printing techniques that are resilient to motion, ensuring that critical repairs and part replacements can be carried out at sea, reducing downtime and bolstering ship selfsustainment abilities.
Shipboard printing system at a glance
One of the systems used onboard is a Haas TM 1 CNC mill paired with a Meltio laser wire print head- a hybrid machine capable of both additive and subtractive manufacturing. The unit measures roughly 9 feet, 8 inches long, 6 feet, 10 inches wide, and over 7 feet tall and weighs up to 5,600 pounds- making motion simulation a critical step without risking damage to the full system. Photo: Johns Hopkins APL / Craig Weiman
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