U.S. Air Force Pumps Another $9 Million Into 3D Systems' Metal LFAM Program

The U.S. Air Force is not done betting on large-format metal 3D printing. It just extended its contract with 3D Systems by another $9 million, bringing total program funding to $27.4 million. The goal is to build a printer big enough and reliable enough to produce flight-ready parts at scale.

The program is called the Large-Format Metal 3D Printer Advanced Technology Demonstrator, or GEN-II DMP-1000. It started in 2023 as a roughly $10.76 million contract, then picked up an extra $7.65 million last year. Each chunk of funding marks a new phase. The latest extension keeps the project on track for completion in September 2027.

Hypersonic Relevance

The work is focused on what the Air Force calls hypersonic relevant capabilities. Translation: parts that can survive extreme heat and stress, likely for next-generation aircraft and propulsion systems. 3D Systems is doing the development at its facilities in Rock Hill, South Carolina, and San Diego, California.

Dr. Michael Shepard, Vice President of Aerospace and Defense at 3D Systems, called the extra money a vote of confidence. "This award increases total project funding to $27.4 million and reflects the U.S. Air Force's continued confidence in our technology, its development path, and our teams," he said. "It has been exciting to see the system come together, and we look forward to working with additional partners on new applications as the platform matures."

What Is the DMP-1000?

Official details are scarce, but the name offers a clue. 3D Systems already sells the DMP Factory 500, a metal printer with a 500 x 500 x 500 mm build volume. The 1000 in GEN-II DMP-1000 suggests the new machine may push closer to one meter in at least one axis. That would make it one of the largest metal powder bed fusion systems the company has put its name on.

The DMP Factory 500 uses three 500-watt fiber lasers. A scaled-up version would presumably add more laser power or a bigger build area, or both. The Air Force wants something that can print large, complex, optimized structures without the tooling and lead times of traditional manufacturing.

Why This Matters

The Air Force has been one of the most aggressive military adopters of additive manufacturing. It has used 3D printing to keep legacy aircraft flying, produce spare parts on demand, and reinforce fragile supply chains. Now it is moving from small-batch repair toward production-scale hardware.

Large-format metal printing is the next hill. Bigger build volumes mean fewer joints, less assembly, and more design freedom. For hypersonic applications, where every gram and every thermal hotspot counts, that freedom is worth the engineering headache.

The GEN-II DMP-1000 is still a demonstrator, not a production line. But the steady funding cadence, $10 million here, $7.65 million there, $9 million now, shows the Air Force thinks the technology is maturing. By late 2027, we will know whether it is ready to leave the lab.