Additive Manufacturing to modernize the US Military

“Innovation” and “force modernization” are the Pentagon buzzwords of the day: Strategies are being developed across the Department of Defense enterprise, with these concepts as the foundational pillars. But oddly enough considering the defense budget of the United States compared to the defense budget of Russia or China, for the first time in decades the United States military apparatus does not possess a clear advantage on the world stage.

¿Causes? The flattening of the technological landscape and emergence of strongly modernized adversaries like Russia and China. Both causes requires that the U.S. innovate to remain dominant not only in technological progress but also in the ability to field systems more rapidly than their peer adversaries.

¿Solutions? Of course, there are not magical solutions, but the undersecretary for research and engineering, Michael Griffin, and other DoD leaders, believe that, in many ways, the Additive Manufacturing could boost the solution. They emphasize this approach in the fiscal 2019 budget request: $90 billion in R&D with increases concentrated in rapid prototyping for testing activities.

For the Pentagon, the Additive Manufacturing can serve as a foundational tool to accelerate new weapons development and provide innovative solutions to win the wars of the XXI Century. Bearing this in mind, industry partners, military operators, and members of the science and technology communities should certainly take notice: DoD leaders are increasingly placing their bets on Additive Manufacturing and they are thinking on using it not only for rapid prototyping in the early stages of development, but also for manufacturing of end-use parts.

Northrop Grumman: Additive Manufacturing for its new LEO Warhead for Hypersonic Missiles

In late March this year at the EMPI Test Facility in Burnet, Texas, Northrop Grumman, using Internal Research and Development (IRAD) funding, demonstrated its new LEO warhead for the first time to customers competing for the DoD hypersonic weapons contracts. This new warhead development marked the first time that the company had made some of its specific warhead components -including the fragmenting inner body- using Additive Manufacturing (AM).

This 50 lb-class warhead has been designed to equip future US air-to-surface and surface-to-surface hypersonic weapons to defeat a broader range of target sets, from ground forces to light/medium vehicles and aircraft.  The new warhead leverages the company's Lethality Enhanced Ordnance (LEO) technology: a scalable fragmentation/penetration warhead solution developed by Northrop Grumman in response to a US Department of Defense (DoD) requirement that by 2019 cluster munitions containing submunitions do not result in more than 1% Unexploded Ordnance (UXO) after arming. Unlike submunitions, LEO technology uses a thinned out shell casing supplemented with an inner fragmentation layer that can be scaled according to the required target set. Northrop Grumman said that in a series of warhead tests with LEO technology achieved the army's stated requirements for area effectiveness, and left behind no UXO.

Raytheon awarded USAF contract to develop 3DELRR

"As the U.S. and other countries look to replace aging battlefield radars with low-cost yet cutting edge and highly capable systems, Raytheon's 3DELRR can meet that growing demand," said Andrew Hajek, Raytheon's 3DELRR Program Director.

"By choosing Raytheon's 3DELRR solution, the Air Force is purchasing an affordable, exportable radar," said David Gulla, Vice President, Global Integrated Sensors at Raytheon Integrated Defense Systems. "Raytheon's 3DELRR design is interoperable with coalition systems and capable of meeting the requirements of many international customers."

Raytheon's 3DELRR system is a Gallium Nitride (GaN)-based radar that operates in the C-band of the radio frequency spectrum. By using GaN, Raytheon was able to affordably increase the radar's range, sensitivity and search capabilities. C-band also offers the military increased flexibility because that portion of the spectrum is relatively uncongested.

The total contract, including all options, is currently estimated at $71.8 million and includes the procurement of an additional three radar systems, for a total of six radar systems and product support. The radar, called the Three Dimensional Expeditionary Long Range Radar, or 3DELRR, is one of the first programs under the DoD's Better Buying Power initiative to be designed for exportability, enabling U.S. forces, allies and security partners to benefit from the system.

3DELRR will replace radars, such as the Vietnam-era AN/TPS-75, which are no longer able to keep pace with current and emerging threats.