AN ADDITIVE BOOST FOR SUB SUPPLY
The U.S. Navy is no stranger to novel 3D printing for submarine production (See Defense Technology Monitor no. 96), and it's now looking to its ally down under to speed up manufacturing. AML3D, an Australia-based specialty 3D printing company, has succeeded in producing copper-nickel tailpieces in just five weeks — far faster than the typical 17-month lead time — thereby demonstrating how additive manufacturing can solve defense supply chain delays. The parts will undergo testing ahead of potential installation. AML3D's defense contracting "Scale Up" Strategy with the DoD has already supplied a reported $16 million in parts by using its WAAM (Wire Arc Additive Manufacturing) method. Officials see this as a key step toward building a resilient, trilateral submarine industrial base. Rear Adm. Jonathan Rucker of the Navy's Naval Sea Systems Command has praised the collaboration as "critical to our ability to build and sustain" the fleet. (3D Printing Industry, January 8, 2025)
3D PRINTING THAT'S OUT OF THIS WORLD
Additive manufacturing in space isn't exactly new. 3D printing has been conducted aboard the International Space Station since 2014. But on-demand space manufacturing still took a leap forward recently with a new prototype developed by researchers at the University of Glasgow's James Watt School of Engineering. Unlike traditional filament-based printers, the system uses granular materials and was successfully tested aboard the European Space Agency's zero-gravity parabolic flight. The technology could reduce the costs and risks of launching pre-built hardware, enabling in-space production of spacecraft parts. Future applications might include solar reflectors, embedded electronics, or even pharmaceutical labs. (BBC News, January 13, 2025)
STARLINK IN CHINA'S CROSSHAIRS...
While SpaceX's 6,700+ Starlink satellites are nominally commercial, their role in Ukraine has spotlighted their military potential — and China has taken notice. In a new simulation, Chinese researchers modeled how to intercept the sprawling constellation, drawing inspiration from whale hunting to create a swarm strategy. Led by Wu Yunhua of the Nanjing University of Aeronautics and Astronautics, the team used a novel AI algorithm to generate a full interception plan in under two minutes. Their analysis suggests that 99 Chinese satellites could approach 1,400 Starlink targets in under 12 hours using lasers, microwaves, or other payloads for surveillance or disruption. (South China Morning Post, January 12, 2025)
...WHILE BEIJING READIES HPM WEAPON
U.S. adversaries have long understood the asymmetric advantage of using electromagnetic energy to cripple American military and civilian infrastructure. However, the main method to release large quantities of electromagnetic energy requires detonating a nuclear weapon at high altitude over the U.S., an act which causes a host of issues and can prove extremely escalatory. Chinese researchers have reportedly pioneered a way to deliver a comparable amount (one gigawatt of energy) through a phased array antenna system. Tests of the high-powered microwave weapon demonstrated no significant degradation after 5,000 pulses. If put into use, the weapon could function in the Ku-band frequencies where Starlink satellites operate. (South China Morning Post, January 14, 2025)
CHAINMAIL, REINVENTED
Until fully automated wars arrive, armor technology still has work to do. DARPA-funded researchers at Northwestern University have developed a new method for linking polymers into an incredibly flexible, lightweight, and durable nanoscale material, ideal for next-generation chainmail-like body armor. The mechanically interlocked polymer contains 100 trillion bonds per square centimeter. In tests, adding just 2.5% of the material to Ultem (a polymer related to Kevlar) dramatically boosted its strength. Scalable production could pave the way for specialty ballistic vests and ultralight protection gear for warfighters and law enforcement personnel. (Science Daily, January 16, 2025)