AML3D to 3D print CuNi nuclear submarine parts for Austal USA
AML3D, an Australian company specializing in Wire-arc Additive Manufacturing (WAM), continues to deepen its support of defense applications through an initial production parts order from Austal USA Advanced Technologies. Valued at about US$355, the order will see AML3D supply high pressure fluid control components for US Navy nuclear submarines made using its ARCEMY platform.
AML3D’s WAM technology has been of particular interest to the defense and maritime sectors due to its ability to rapidly produce large-scale, near-net-shape structures from a variety of metal feedstocks, including aluminum, titanium, copper, steel, stainless steel, and nickel alloys. In the context of the recent Austal USA order, AML3D will be producing parts from a copper-nickel alloy (CuNi) following a successful qualification program for the material.
CuNi is a commonly used alloy in maritime applications thanks to its combination of high corrosion resistance (particularly to salt water) and low macrofouling rates. Historically, CuNi parts have been made using conventional metal forming processes like casting, however additive manufacturing has in recent years presented a beneficial alternative that has faster lead times and less supply chain complexity.
To fulfil the order, AML3D will produce three large-scale, high-pressure fluid control components for nuclear submarines at its US headquarters in Stow, Ohio. The details of the document state that 50% of the contract value is to paid upfront, and the other half paid upon delivery, testing, and commissioning of the production parts. This is expected to happen by the end of Q3 2027.
“It is exciting to deliver parts that directly support the US Navy nuclear submarine programs,” said AML3D CEO Sean Ebert. “AML3D has been diligently delivering component and materials qualification and test programs for the US Navy over several years. We have always known that our WAM technology produced parts that match and regularly exceed traditional manufacturing. We view this order for production parts from Austal USA as a strong endorsement of our WAM technology.”
AML3D has been building strong ties within the American defense industry, specifically its the submarine industrial base. Just a few months ago, for instance, the company delivered two custom ARCEMY systems to HII’s Newport News Shipbuilding (NNS) division following an order placed in late 2025. The company is now working on fulfilling an additional machine order from NNS, worth about US$ 7 million, for four more custom WAM platforms. In total, AML3D says that it has deployed 16 systems to support the US Navy submarine industrial base.
As the Austal USA initial production parts order shows, machine sales only represent part of AML3D’s offering: it also takes orders for parts. For instance, the company also has a contract with BlueForge Alliance to supply non-safety-critical submarine replacement parts made from a NAB alloy. You can read more about AML3D’s activities within the submarine and defense sectors in our recent LFAM ebook.
