Marines 3D print Coast Guard boat part in hours during Korea exercise

U.S. Marines with 3rd Marine Logistics Group used additive manufacturing to produce a replacement component for a U.S. Coast Guard watercraft during the Combined Joint Logistics Over-the-Shore 26 (CJLOTS 26) exercise in Pohang, South Korea, printing a part that was not immediately available through standard supply channels.

CJLOTS 26 trains U.S. and Republic of Korea forces to transfer personnel and equipment from sea to shore in austere environments. When a Coast Guard vessel needed the part, Marines with 3rd Maintenance Battalion, Combat Logistics Regiment 35, 3rd MLG, took on the job using their expeditionary fabrication systems.

“There is a demand to decrease the supply deficiencies and backorders in order to increase repairs and replenish items quickly,” said Chief Warrant Officer 2 Jonathan B. Salas, Utilities Officer for Regional Maintenance Operations Company North, 3rd Maintenance Battalion. 

“Advanced manufacturing is one answer to solve this problem set. In this case, we cut a potential two- to three-week shipping delay for a replacement part down to just a few hours. The replacement part itself cost about $12 to print, the same as the original, but we have the option to use a cheaper filament that would cut the cost by another $4 without sacrificing performance.”

Reverse-engineered and printed on site

Working out of an Expeditionary Fabrication Facility, or X-FAB, the Marines 3D printed the replacement part by reverse-engineering the original piece in their design systems. After minor adjustments, the part was installed. It worked, and the watercraft resumed its role in the exercise.

“The immediate effect that the 3D printed part provided to the mission was expediting the continued use of the Coast Guard’s rigid-hull inflatable boats, valued at around $600,000 each,” Salas said. “This allowed the Coast Guard to operate quick-reaction-force and patrol missions, ensuring the security of the surrounding waters for CJLOTS.”

“The first prototype was a success; they were taken aback by the fact that a part such as their strainer can be reverse-engineered and 3D printed in full in less than half a day,” said Cpl. Kenzie Gallang, a metal worker with the battalion.

A model for joint and allied sustainment

The Marines said the capability gives the Republic of Korea-U.S. alliance a way around traditional supply chains for some repairs: build the part on site, and keep equipment running in the field.

“We are demonstrating how non-traditional manufacturing methods, even in an expeditionary environment, can produce parts of consequence to improve the readiness across the joint force,” said Col. Robert Fairley, commanding officer of Combat Logistics Regiment 35.