The U.S. Army is implementing 3D printing technology to address vehicle maintenance challenges through its Battle Damage Repair and Fabrication (BDRF) process. This initiative combines computer-aided design with additive manufacturing to produce temporary replacement parts for ground vehicles, particularly focusing on components with long procurement times or obsolete status.
The program, led by the U.S. Army Tank-automotive Armaments Command (TACOM), represents a collaboration between multiple Army divisions including the DEVCOM Ground Vehicle Systems Center and Rock Island Arsenal. Since early 2024, the team has successfully produced and approved parts for nearly four dozen product lines, with units already installing these components to restore vehicles to operational status.
The scope of the project is significant, with GVSC conducting assessments of more than 40,000 vehicle parts and developing over 600 3D CAD models for manufacturing. These digital models are stored in a database, enabling on-demand production of replacement parts to support vehicle lifecycle sustainment.
“Units are installing those parts on vehicles and bringing equipment back to mission-capable status,” said Michael Hansen, TACOM’s advanced manufacturing lead. Hansen noted that some temporary replacement parts have performed better than original components in testing, leading to their consideration as permanent supply alternatives.
The initiative has prompted further development of advanced manufacturing capabilities, including the opening of GVSC’s Advanced Manufacturing Commercialization Center (AMCC) in 2023. The AMCC supports production efforts with specialized equipment, including a hybrid metal additive manufacturing machine for Jointless Hull components.
Source: army.mil
