U.S. Navy Demonstrates Shipboard 3D Printing on Warship to Strengthen Expeditionary Logistics at Sea.

The U.S. Navy is showing how onboard 3D printing can transform expeditionary logistics during RIMPAC 2026, with the amphibious assault ship USS Essex (LHD 2) manufacturing critical replacement parts and mission-specific tools directly at sea. Demonstrated during the multinational exercise, the capability reduces reliance on vulnerable supply chains while keeping ships and Marine forces operational during extended deployments.

By producing components on demand alongside Combat Logistics Battalion 13 of the 13th Marine Expeditionary Unit, USS Essex can restore equipment faster and sustain combat readiness without waiting for shore-based resupply. The demonstration highlights how additive manufacturing is becoming a practical force multiplier for distributed maritime operations, improving resilience, operational endurance, and logistical flexibility in contested environments.

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A digitally crewed uncrewed surface vessel departs Sand Island near Honolulu, Hawaii, carrying components for an embarked additive manufacturing system aboard the Wasp-class amphibious assault ship USS Essex (LHD 2) during Exercise Rim of the Pacific (RIMPAC) 2026 on July 7, 2026. (Picture source: U.S. Department of War/Defense)

The initiative is being showcased as one of approximately 40 experimentation projects conducted under the Fleet Experimentation Program (FLEX) during RIMPAC 2026 in Hawaii. Organized under the sponsorship of the U.S. Navy and the U.S. Department of War, the experimentation campaign exposes operational forces to emerging technologies while collecting real-world feedback to accelerate future acquisition and modernization decisions.

Unlike conventional naval logistics, where replacement parts may take weeks to reach deployed warships or may no longer be commercially available, the embarked manufacturing cell aboard USS Essex enables technicians to digitally recreate components and produce them on demand. The approach directly addresses one of the most persistent operational vulnerabilities faced by forward-deployed naval forces: maintaining aging equipment while operating thousands of kilometers from established maintenance hubs.

The manufacturing workflow combines both additive and subtractive production techniques. Maintenance personnel first identify damaged or obsolete components before the 3D printing team measures the original item or digitally captures it using high-resolution 3D scanning technology. Engineers then create a computer-aided design model and initially produce a plastic prototype to validate dimensions, fit, and functionality. Once verified, the final component can be manufactured from materials suitable for operational use, dramatically shortening repair timelines while minimizing material waste.

According to Gunnery Sgt. Samuel Margarini, who leads the 3D printing team within Combat Logistics Battalion 13, said the capability allows Marines and sailors to solve engineering challenges immediately rather than waiting for conventional procurement processes. The onboard manufacturing cell supports requirements from multiple communities aboard Essex, including ship engineering, Marine Corps equipment maintenance, and aviation support.

The system also transforms the way supply departments manage inventory during deployment. Rather than maintaining extensive stocks of rarely used components or relying on lengthy procurement channels, digital manufacturing shifts inventory toward digital part libraries that can be produced on demand. Cmdr. Jason Pirrallo, USS Essex's supply officer, noted that manufacturing replacement components directly aboard ship reduces administrative processing associated with ordering, tracking, receiving, and distributing spare parts while lowering procurement costs across multiple departments.

From a military logistics perspective, this capability represents an important evolution toward distributed sustainment. Future naval operations in contested environments, particularly across the Indo-Pacific, are expected to face increasing threats against supply ships, ports, and long-distance logistics networks. Organic manufacturing capabilities reduce reliance on vulnerable supply lines and allow deployed forces to sustain operations independently for longer periods.

The value of the technology is especially significant aboard amphibious assault ships such as USS Essex, which serve as multi-mission expeditionary vessels capable of supporting amphibious assaults, aviation operations, humanitarian assistance, disaster relief, and medical response missions. The ability to rapidly manufacture mission-essential components increases operational flexibility across every mission set the ship performs.

Medical readiness is emerging as one of the most promising applications for onboard manufacturing. As the USS Essex frequently operates as a forward-deployed medical support ship during humanitarian assistance operations, maintaining specialized medical equipment is critical. Many medical devices rely on low-volume replacement components that are difficult or expensive to source through conventional suppliers, particularly when manufacturers discontinue production.

Capt. David Foster, the ship's senior medical officer, explained that the manufacturing team has already produced replacement thermostat covers and oxygen storage system components that were no longer commercially available. Future development efforts could extend to producing sterilizable medical devices and patient-care equipment aboard deployed warships, potentially transforming medical sustainment during expeditionary operations and disaster response missions.

The operational significance extends beyond simple replacement parts. Additive manufacturing allows engineers to fabricate custom-designed tools optimized for specific maintenance tasks, prototype new engineering solutions, and rapidly modify equipment to meet unforeseen operational requirements. This flexibility enables maintenance teams to respond to unique challenges without waiting for shore-based engineering support or manufacturer involvement.

For the U.S. Navy and U.S. Marine Corps, the technology aligns closely with broader modernization initiatives emphasizing expeditionary advanced base operations (EABO) and distributed maritime operations (DMO). Both operational concepts require smaller, geographically dispersed units capable of remaining self-sufficient despite limited logistical support. Organic manufacturing capabilities directly reinforce these concepts by reducing dependency on centralized supply networks.

The experimentation aboard USS Essex also contributes valuable operational data to the Fleet Experimentation Program, allowing engineers and acquisition officials to evaluate how additive manufacturing performs under real deployment conditions rather than laboratory environments. Operational feedback collected during RIMPAC can influence future procurement strategies, manufacturing standards, certification procedures, and fleet-wide implementation of expeditionary production capabilities.

The U.S. military has steadily expanded investment in expeditionary manufacturing over the past decade, integrating portable additive manufacturing systems across naval vessels, expeditionary logistics units, and forward operating bases. The objective is not to replace traditional industrial production but to complement existing supply chains by producing mission-critical components when speed outweighs conventional procurement efficiency.

As geopolitical competition increasingly focuses on the Indo-Pacific, logistics resilience has become as strategically important as combat capability itself. The ability to manufacture critical components aboard warships could provide a decisive advantage during prolonged operations where access to industrial support cannot be guaranteed. Instead of measuring readiness solely by stocked inventories, future naval forces may increasingly rely on digital manufacturing ecosystems capable of producing thousands of certified components on demand.

The demonstration aboard the U.S. Navy USS Essex illustrates how additive manufacturing is evolving from an experimental engineering tool into an operational capability that directly supports combat readiness, reduces lifecycle sustainment costs, and enhances force resilience. As the technology matures and certification expands to include more complex metallic and medical components, embarked manufacturing is likely to become a standard capability across future U.S. Navy expeditionary fleets, strengthening their ability to sustain operations in contested maritime environments without relying on fragile global supply chains.

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Written by Alain Servaes – Chief Editor, Army Recognition Group
Alain Servaes is a former infantry non-commissioned officer and the founder of Army Recognition. With over 20 years in defense journalism, he provides expert analysis on military equipment, NATO operations, and the global defense industry.