US Navy Installs First Welded 3D Printed Metal Part on Operational Submarine

In a landmark moment for additive manufacturing in defense, Portsmouth Naval Shipyard has successfully installed the first welded 3D printed metal component on an operational U.S. Navy submarine.

A Virginia-Class Milestone

The copper-nickel flange, produced via metal additive manufacturing, was welded aboard the USS Washington (SSN-787), a Virginia-class attack submarine. This marks the first time an AM-produced component has been certified, welded, and installed on an in-service submarine in the Navy's fleet.

"The unique nature of this momentous achievement is a testament to the strong teaming and innovation that PNSY is known for," said Cpt. Jesse Nice, shipyard commander.

Rapid Production, Faster Maintenance

The component was produced significantly faster than traditional manufacturing methods would allow, reducing supply chain delays and supporting faster maintenance timelines for the Navy's aging submarine fleet.

This development aligns with the chief of naval operations' focus on strengthening domestic foundry capabilities and the shipyard's commitment to deckplate-led innovation.

Growing Navy AM Adoption

The milestone follows a series of AM investments by the Navy: Velo3D's $9.8M Department of War contract, AML3D's submarine component orders, and ongoing work at Corpus Christi Army Depot on Black Hawk helicopter parts. The Navy is increasingly turning to additive manufacturing to address obsolescence issues and accelerate supply chain resilience.

For the defense 3D printing sector, this installation represents a significant validation of AM's readiness for critical naval applications.