How the 3D Printing in the Defense Industry Improves Operational Readiness Across Military Branches

At Fort Irwin, Army regiments use Continuous Fiber Reinforcement (CFR) technology to print everything from personal protective equipment (PPE) to vehicle components. 

One notable success: a discontinued hatch plug, essential for night operations, previously cost $10,000 and had a 3-month lead time. With Markforged Onyx and 17-4PH stainless steel, the Army reproduced the part for less than $1,000, saving over $244,000 while ensuring operational readiness. 

Key Army Benefits: 

• Rapid replacement of obsolete parts
• Stronger, lighter mission-critical equipment
• Reduced cost and downtime

At Cannon Air Force Base, airmen in the 27th Special Operations Wing use composite 3D printers to lighten their load in combat training. 

By replacing heavy tools with carbon-fiber reinforced nylon equivalents, airmen improved stamina and agility. The base also prints custom night vision goggle (NVG) mounts for less than $5 each — mounts that are “just as strong” as aluminum versions costing hundreds of dollars and taking weeks to ship. 

Key Air Force Benefits: 

• Lightweighting of field tools
• Faster and cheaper replacement parts
• Greater agility in combat training

Through programs such as AFLOAT, the Navy has deployed industrial 3D printers directly on ships, enabling sailors to print tools, fixtures, and replacement parts at sea. 

Instead of expediting shipments across the globe, crews can fabricate components onboard—reducing downtime, improving fleet readiness, and ensuring operational independence in remote waters. 

Key Navy Benefits: 

• Shipboard part production
• Strong, repeatable components in harsh environments
• Increased supply chain resilience

Marine Corps Additive Manufacturing Specialists (MOS 6044) leverage composite and metal 3D printers to fabricate on-demand parts for vehicles, drones, and weapon systems. 

By skipping multi-week lead times and printing with continuous fiber reinforcement, Marines ensure that critical components are available in hours, not months—directly at the point of need. 

Key Marine Corps Benefits: 

• Field-deployable additive manufacturing
• Durable composite and metal parts for rugged conditions
• Faster turnaround for mission-critical equipment

Beyond combat readiness, the Department of Veterans Affairs (VA) is using 3D printing to improve veterans’ quality of life. 

The Central Virginia VA Health Care System produces rigid prosthetics with Onyx and flexible prosthetics with TPU 95A, delivering customized, durable solutions for wounded warriors. As one VA engineer put it: “These printers just work, and enable us to deliver high-quality outcomes for our patients.” 

Key VA Benefits: 

• Affordable, customizable medical devices
• Faster patient turnaround
• Improved veteran quality of life

Markforged provides the U.S. military with:

• Composite & Metal Printing: From lightweight Onyx to 17-4PH stainless steel.
• Continuous Fiber Reinforcement (CFR): Parts up to 10x stronger than plastics, rivaling aluminum.
• High-Temp Materials: ULTEM™ 9085 and Vega™ for aerospace and naval use.
• Security Compliance: ISO 27001 certified, STIG-compliant, with encrypted print workflows.
• Training at Scale: Markforged University ensures operators are deployment-ready fast.

From combat readiness to veteran care, 3D printing in the defense industry is reshaping how the U.S. military operates. Whether replacing legacy parts, reducing equipment weight, or printing at sea, Markforged additive manufacturing delivers strength, speed, and security—where and when it matters most. 

Learn how Markforged can help your defense organization achieve mission readiness. Contact us today to get started.