Case Study of the Naval Surface Warfare Center Indian Head Additive Manufacturing Initiative

Abstract

Additive manufacturing (AM) is a manufacturing paradigm revered by the United States with inspired interest, as the Department of Defense (DOD) strategizes to revitalize its industrial bases. AM is a vital component of the DOD strategic initiatives to implement an agile supply and logistics framework. The Office of Naval Research, in collaboration with the Naval Surface Warfare Center Indian Head Division, is conducting the Energetic Materials Additive Manufacturing (EMAM) study. The catalysts for the study are the high rate of anomalies and constraints of traditional manufacturing. The EMAM study objective is to determine the efficacy of two AM methodologies, Direct Ink Write and Digital Light Processing, in relation to the manufacturing of propellant. Painter suggests the long-term goal is to field the AM product upon the successful completion of design verification testing and qualification. EMAM research indicates that AM of propellant is a viable alternative to traditional manufacturing. The Direct Ink Write methodology is a feasible solution to address the Hercules Experimental Smokeless 5808 quality concerns, while fostering sustainable practices. An evaluation of the EMAM project concluded that a cost–benefit analysis, formalized processes, and protocols are necessary to establish a formalized acquisition program. The investment of resources will enable future research and development, technological advancement and warfighter readiness.