The Digital Manufacturing Centre (DMC) has completed production of its largest additive manufacturing metal component to date – a 90kg suspension and differential carrier for the Mastiff military vehicle. The part was produced for NP Aerospace as part of the UK Ministry of Defence’s TAMPA Spiral 2 project. The component will be displayed at NP Aerospace’s stand at DSEi 25 in London from September 9-12, 2025.
The component was manufactured using Wire Arc Direct Energy Deposition (DED) technology. Each side measures approximately 500mm in cube dimensions and weighs about 90kg. Unlike typical additive manufacturing applications focused on weight reduction, this project aimed to prove that 3D printing could replicate the performance of traditionally cast, forged, or fabricated structural components.
The primary benefits of using additive manufacturing for this application include eliminating expensive tooling costs and reducing lead times from 6-9 months to weeks. DMC engineered and validated the manufacturing process while ensuring compliance with military specifications. The project demonstrates the potential for 3D printing to support rapid development cycles for military platforms.
“As a key partner on critical UK MoD projects it is important we advance technology that has very real benefits in the field. By working with DMC on TAMPA Spiral 2 we are able to demonstrate significant platform availability improvements and reduced lead times and costs on part replacement,” said David Wilson, Director of Engineering at NP Aerospace. Wilson noted that the DED technology also offers capabilities for repairing and machining existing parts, potentially extending component life.
Kieron Salter, Founder & CEO of DMC, stated: “At DMC we are very pleased to have been intimately involved with Project TAMPA from the outset to help UK MoD better understand the capabilities, potential and benefits that using AdM can bring to the defence supply chain and critically, what additional design and engineering expertise DMC can also deliver.”
Source: digitalmanufacturingcentre.com
