In our last article on the GovDesignHub, Kimberly Gibson, Industrial Base Integration Director at America Makes—a public-private partnership dedicated to accelerating additive manufacturing (AM) adoption and supporting global U.S. manufacturing competitiveness—introduced the Ohio Innovation Hubs program and explained how the newly constructed hub in Youngstown is poised to drive AM forward.
These exciting Innovation Hubs are being introduced at a critical time. For years, the shift of domestic manufacturing to international facilities has impacted U.S. production capacity and revealed vulnerabilities in critical supply chains—especially in the defense and aerospace sectors.
In high-stakes environments, delays from equipment failures or outdated manufacturing processes can be costly and dangerous. Fortunately, advanced manufacturing technologies and capabilities—including AM—have the potential to make these challenges a thing of the past.
AM—most commonly known as 3D printing—has long held transformative potential, enabling manufacturers to make products at the point of need and fabricate products with designs that would be too challenging or complex for traditional manufacturing practices.
In the second part of our discussion, Kimberly highlights how AM could play a transformative role in the defense and aerospace sectors—unlocking new capabilities, strengthening supply chains, and enabling faster, more agile production.
GDH: What potential use cases exist for additive manufacturing in the defense industry?
Kimberly Gibson: AM is changing the nature of how things are made. It enables manufacturing at the point of need, from building structures with additive construction to creating custom medical devices and surgical guides. As technology evolves, we’ll see entirely new material combinations that aren’t possible or cost-effective with traditional manufacturing.
One of AM’s biggest advantages is rapid prototyping and customization, which allows for quick production of weapons, equipment, and components, making testing and iteration much faster. It’s also a game-changer for on-demand spare parts, especially in high-stakes environments like battlefields or remote locations, where reducing downtime is critical.
Beyond speed, AM makes it possible to create lightweight yet durable materials, perfect for drones, aircraft, and combat vehicles where every ounce matters. Moreover, it strengthens supply chain resilience by decentralizing production and reducing reliance on traditional supply routes.
In defense, AM is being used for unmanned systems, producing parts for unmanned aerial vehicles (UAVs), ground robots, and other autonomous tech. And the innovation doesn’t stop there — imagine 3D-printed military barracks, advanced soldier helmets, and even submarine hulls. The possibilities are significant, making AM a powerful tool for tackling some of the military’s toughest challenges.
GDH: Why is this technology an exciting one for the Department of Defense (DoD) and the Defense Industrial Base (DIB)?
Kimberly Gibson: The U.S. industrial base is at a turning point, facing an urgent need to rethink how we manufacture critical goods. For decades, offshoring and a focus on cheap labor have weakened domestic production and exposed vulnerabilities in our supply chains—especially in the defense sector.
Now, the DoD is looking for innovative solutions to rebuild resilience, and one of the most promising technologies leading the way is AM. This cutting-edge technology is transforming how military equipment is made, allowing for the rapid production of complex and customized parts.
For example, imagine a warfighter in a remote location facing a critical equipment failure—something that once took weeks to fix while waiting on a part from a distant supplier. With AM, that same soldier can print the part on-site, reducing downtime and keeping the mission on track.
AM is revolutionizing operational efficiency while reducing the DoD’s dependence on foreign manufacturing. By adopting this technology, the defense sector can design and produce essential equipment right here in the U.S., creating a more self-sufficient, agile, and resilient supply chain.
Looking ahead, embracing AM isn’t just a good idea — it’s a necessity. Investing in this technology ensures that the U.S. defense sector stays strong, flexible, and ready to meet the challenges of an ever-changing world.
GDH: What about the aerospace industry? What areas of growth do we see for additive manufacturing in aerospace?
Kimberly Gibson: AM is transforming the aerospace industry by making it easier to produce advanced, lightweight parts and cutting-edge propulsion hardware — all while reducing development time. Its ability to quickly print, test, and refine designs makes it a game-changer for creating high-complexity components that are critical in aerospace. With AM, innovation moves faster, designs get better, and the entire process becomes more efficient.
But there’s still plenty of room to grow. Expanding the range of printable materials—like high-performance alloys and composites—while improving durability and heat resistance will be key. Streamlining the qualification and certification process will help meet strict aerospace standards without slowing innovation.
At the same time, boosting production speed, developing larger build platforms, and improving automation will make AM more scalable and efficient. Smarter design approaches, like optimizing parts specifically for AM instead of retrofitting traditional manufacturing methods, will unlock even greater potential.
Equally important is seamlessly integrating AM with traditional manufacturing techniques like machining, casting, and injection molding to create hybrid approaches that enhance production efficiency and cost-effectiveness. By combining AM’s design freedom with the precision and scalability of conventional methods, manufacturers can optimize performance while reducing material waste and lead times.
Cost reduction is another priority, from lowering material and equipment expenses to improving post-processing efficiency. Strengthening AM supply chains and establishing decentralized production hubs will support on-demand manufacturing and improve resilience.
Finally, sustainability efforts—like better recycling systems and eco-friendly material options—will help reduce waste and make AM a greener solution. By focusing on these areas, AM can push aerospace and defense innovation even further, leading to lighter, stronger, and more efficient components for the future.
To read the first article in our two-part Q&A series with Kimberly, click HERE.
