Disruptive Technologies through Novel Additive Manufacturing (NAM) Focus Area
Abstract
NAM enables on-demand production of critical parts and supplies for deployed units that augment platforms, weapons, sensors, and other solutions to modernization challenges. Targeted investments accelerate capabilities to the warfighter and realize new disruptive technologies through low cost, rapid innovation, leveraging technology innovation from small businesses and non-traditional performers. In FY 2023, I&M selected, executed, and transitioned multiple NAM projects, including: •3D Printed Radiation Shielding of Electronic Components: This project investigated and developed a novel approach to mitigate radiation damage to microelectronic systems in extreme environments using unique additive manufacturing techniques. The project enables the DoD to integrate COTS electronics into emerging space systems at a significant SwaP advantage. In FY 2023, the project successfully manufactured radiation shielding materials that were tested for performance against proton, gamma ray, and heavy ion induced damage. This dataset was used to outline design rules for space systems travelling in low Earth orbit trajectories. Development of the prototype capability continues in FY 2024, using FY 2023 funds, to model the performance of the shielding materials for medium Earth orbit and geostationary orbit trajectories before transitioning to DoD and interagency partners. •Arctic Grid Energy Storage (AGES): This project developed and demonstrated a battery storage and tactical generator microgrid capability that meets critical operational requirements in extreme cold weather environments; emphasizing scalable, flexible, and high-power quality for continuous and high-energy demands. In FY 2023, preliminary, interim, and detailed design reviews were completed; final designs were provided; and operational testing was completed. Work continues in FY 2024, using FY 2023 funds, to deliver and demonstrate a hybrid operational energy microgrid at the Alaska Cold Region Research and Engineering Laboratory (CRREL) site during a North American Aerospace Defense Command (NORAD) and U.S. Northern Command (USNORTHCOM) field exercise, and for testing at the New Hampshire CRREL site. Final transition occurs in FY 2024 to NORAD, USNORTHCOM, Army Futures Command, and Army North (ARNORTH). •Intelligent Sensing for Remote and Field Care: This project prototyped an innovative ultrasound imaging system to enhance small unit medical self-sufficiency at the tactical edge in support of future distributed warfighting concepts. These concepts involve units separated by large geographic distances and operating in austere environments with area denial challenges, which necessitate the need for intelligent medical devices that support trauma care in the field. In FY 2023, the project focused on designing and maturing the prototype. The hardware components were received, and the project completed initial testing and design fabrication prior to transitioning to the Trauma Care in a Rucksack (TRACIR) project under USSOCOM, with the Joint Services identified as initial users. •Tactical Microgrid Standard Environmental Control Unit (TMS ECU): This project developed a TMS compliant controller for ECUs enabling networked capability to optimally operate heating and cooling equipment, reducing power demand and fuel consumption. In FY 2023, remote control of the ECU was demonstrated utilizing the TMS and the control algorithm design for the microgrid controller and the microgrid dashboard design were completed. Development work continues in FY 2024, using FY 2023 funds, concluding with a final demonstration before transitioning to the U.S. Army Program Manager Expeditionary Energy and Sustainment Systems (PM E2S2) to inform future procurement of ECUs and other smart TMS loads. •Small 3D Printed Unmanned Aerial Vehicles (UAVs): This project develops a low-cost UAV utilizing a low-cost sensor array, COTS parts, and 3D printing to reduce cost. In FY 2023, the project focused on reducing risk for the guidance capability and demonstrating range and sensing. In FY 2024, using FY 2023 funds, the project will focus on end-to-end development and high-fidelity sensing before transitioning to DoD partners. •AM-Enhanced Lattice Castings: This project uses distributed desktop-scale additive manufacturing to create casting patterns, deploy casting methodologies, and generate large-scale intricate lattice-enhanced design concepts. In FY 2023, sub-scale, multi-segment, lattice-enhanced cast engineering articles were successfully designed, segmented, additively manufactured, cast, and tested at relevant experimental conditions. Work continued in FY 2024 before transitioning to the Defense Threat Reduction Agency (DTRA).
Document Details
- Document Type
- Accomplishment
- Publication Date
- Oct 01, 2025
- Source ID
- effd450bc1fe744771a41427fa1ae8e8