US Navy Deploys First Metal 3D Printer at Sea

The Xerox ElemX 3D metal printer has been installed on USS Essex (LHD 2) and at-sea trials have begun in the Pacific Rim By DA Staff / 21 Jul 2022

Discover Leading Defense Technology Solutions

Discover cutting-edge solutions from leading global suppliers
SUPPLIER SPOTLIGHT
US Navy Deploys First Metal 3D Printer at Sea
Follow DA

Xerox Elem Additive Solutions has announced that its ElemX liquid metal printer has been installed on board USS Essex (LHD 2), claiming that it is the first metal additive manufacturing machine deployed on a US Naval vessel.

This installation is the latest step in the US Navy’s strategy of using Additive Manufacturing (AM) to increase operational readiness for the fleet. It will also build on the relationship between the US Navy and Xerox Elem Additive that began with the Naval Postgraduate School in Monterey, California receiving the first-ever installation of the ElemX in 2020.

“The military supply chain is among the most complex in the world and putting the ElemX on USS Essex means that sailors can now bypass that complexity and print parts when and where they need them,” said Tali Rosman, GM of Elem Additive. “We are proud to continue our partnership with the Navy to help them advance their additive manufacturing capabilities and execute their long-term vision.”

The ElemX leverages Xerox’s liquid metal AM technology that uses standard aluminum wire. Unlike other metal 3D printing technologies, there are no hazardous metal powders with ElemX and no need for special facility modifications or personal protective equipment to operate the machine. The printer also requires minimal post-processing and therefore provides a faster time-to-part. This ability to produce reliable replacement parts on-demand reduces the dependency on complex global supply chains for deployed forces.

To withstand various sea states and environmental challenges that US naval warships encounter, the ElemX was installed in an industrial shipping container to ruggedize it. 

Currently at sea on board USS Essex, trials have already begun to establish operational guidelines and technical feasibility studies to determine applications and use cases. A team on board USS Essex will design and print shipboard items and provide feedback to NPS and Commander, Naval Surface Force Pacific (COMNAVSURPAC).

The ElemX 3D printer was commercially introduced in February 2021, and since then, Elem Additive Solutions has expanded operations, including opening an Additive Manufacturing Center of Excellence in Cary, North Carolina. The ElemX is a safe and simple metal 3D printer, addressing supply chain resiliency for transportation, aerospace, defense and industrial manufacturing and engineered to bring simplicity to the supply chain process.

Posted by DA Staff Connect & Contact

Latest Articles

Meltio Expands Additive Manufacturing Distribution Network in Portugal

Meltio has announced a new strategic partnership with PrimeOut to expand its presence in Portugal’s metal additive manufacturing market

May 02, 2025
New Mobile Troposcatter Technology Supports GPS Denied Operations

Spectra Group is set to unveil a mobile troposcatter solution enhancing Comtech’s COMET system, delivering high-bandwidth, satellite-independent communications in contested and GPS-denied environments

May 02, 2025
Micropol Expands Tactical Communications Capabilities with New Production Facility

Micropol Fiberoptic is expanding its tactical communications capabilities with a new high-capacity production facility strategically located along Sweden’s E6 highway in Halmstad

May 02, 2025
ALE: Secure Battery Solutions for DoD & Aerospace Systems

American Lithium Energy (ALE) is a trusted provider of secure, high-performance batteries, delivering essential power solutions to the U.S. Department of Defense and other high-demand sectors

May 02, 2025
Partnership to Enhance Networking Capabilities for Defense Platforms

Amphenol Aerospace and BotBlox have partnered to distribute and integrate compact, rugged Ethernet hardware for defense platforms, enhancing networking capabilities and accelerating product development for uncrewed and mobile systems

May 01, 2025
USMC Receives Extended Range MQ-9A Reaper® from GA-ASI

The U.S. Marine Corps has received a technologically advanced MQ-9A Reaper® UAS from GA-ASI, featuring wing-borne fuel pods and reinforced landing gear for extended 30+ hour endurance

May 01, 2025

Featured Content

Partnership to Enhance Networking Capabilities for Defense Platforms

Amphenol Aerospace and BotBlox have partnered to distribute and integrate compact, rugged Ethernet hardware for defense platforms, enhancing networking capabilities and accelerating product development for uncrewed and mobile systems

May 01, 2025
Sky Power to Showcase ISR UAV Propulsion Technology at XPONENTIAL 2025

Sky Power International will present advanced UAV propulsion technologies at XPONENTIAL 2025, highlighting powerful engines, hybrid systems, and customized solutions for ISR and civilian applications

Apr 29, 2025
Q&A with DEFCROS: Key Insights for the 2025 Expo

DEFCROS Founder Kristijan Ilovača discusses the expo’s rapid growth, international ambitions, and how the event aims to support defense and security innovators

Apr 24, 2025
Advancing Defense Capability Through Strategic Collaboration Defense Advancement works with major OEMs to foster collaboration and increase engagement with SMEs, to accelerate innovation and drive defense capabilities forward.