3D Systems Lands $9M Air Force Contract for Large-Format Metal 3D Printing

The Air Force keeps betting on big metal prints

The U.S. Air Force just handed 3D Systems another $9 million. This latest award extends the Large-Format Metal 3D Printer Advanced Technology Demonstrator program, also known as GEN-II DMP-1000, for two more years. Total project funding now sits at $27.4 million.

Work will continue at 3D Systems facilities in San Diego and Rock Hill, South Carolina. The goal is to prove that large-scale metal 3D printing can produce flight-critical parts at scale. Think high-temperature alloys, high-speed deposition, and hardware that could eventually replace traditional forging and machining for certain defense components.

What the GEN-II DMP-1000 actually is

The program started back in 2023. Phase one proved out the basic technology. Phase two, which wrapped up recently, pushed toward flight-relevant applications. This new phase is supposed to finish the demonstrator outright and hand the Air Force a qualified system it can evaluate for operational use.

3D Systems has not released many technical specifics. We do know the machine uses direct metal printing and targets a 500mm-cubed build volume. That lines up with the company's DMP Factory 500 platform, already on the market for industrial customers. The Air Force money is going toward making that platform suitable for aerospace-grade production.

Why this matters beyond defense

3D Systems projects that Aerospace and Defense will be its fastest-growing industrial segment in 2026. The company expects more than $35 million in revenue from production systems and custom metal parts. A qualified large-format platform would open up entirely new categories of work: engine brackets, structural fittings, tooling for other manufacturers.

The military contract also de-risks the technology for commercial buyers. When the Air Force funds the qualification process, civilian customers get a machine that has already been vetted under strict standards. That is a powerful sales argument in industries like aerospace, energy, and heavy manufacturing.

The competition is not standing still

Markforged, now part of the larger Nano Dimension family, has been pushing continuous fiber and metal deposition for industrial clients. Velo3D is selling its qualified metal systems to aerospace customers. Trumpf and EOS both have large-format metal platforms with strong European defense ties. The Air Force award keeps 3D Systems in the conversation, but it does not lock up the market.

What it does do is validate the thesis that large-format metal 3D printing is mature enough for flight-critical hardware. The next two years will show whether the GEN-II DMP-1000 can move from demonstrator to production workhorse. If it does, 3D Systems gets a flagship product with a military pedigree. If it stalls, the Air Force still learns something, and the next contractor gets the follow-on order.

For anyone watching industrial additive manufacturing, this is one of the programs to track. The technology is real. The funding is stable. Now we need to see the parts actually fly.