Meet the six* companies enabling deployable 3D printing in the battlefield

As warfare shifts toward decentralization, speed, and resilience, a new generation of rugged, deployable 3D printing systems is helping military units produce spare parts, tools, and even entire unmanned systems at the point of need. The six* companies featured here—Markforged, SPEE3D, Xerion, BigRep, Firestorm Labs and Craitor—represent a cross-section of innovation in this space. While the first four companies have broader commercial portfolios, the latter are mission-specific ventures focused solely on defense applications. Together, they are reshaping what’s possible on the frontlines with deployable 3D printing for the battlefield.

Markforged – X7 Field Edition

Markforged’s X7 Field Edition is a field-deployable version of its industrial 3D printer, designed for tough, disconnected environments where traditional supply chains break down. Housed in a Pelican AL3232 single-lid case (with custom foam modules and moving component locks to mitigate damage during transport), the X7 FE enables units in remote or tactical environments to print parts on demand using high-strength composite materials.

Across various branches of the U.S. military, Markforged systems have been used to tackle two main challenges: replacing obsolete legacy components and producing lightweight, custom parts. For example, the Army leveraged additive manufacturing to replace discontinued hatch plugs for combat vehicles in days rather than months. The Air Force regularly prints components for B-52 bombers and C-5M aircraft, while the Navy has begun printing parts directly aboard ships like the USS Tulsa. In addition, the X7 FE solution has been included in MIL-STD-810 testing in support of a DoD Program of Record.

The X7 FE can be fully set up and ready to print in minutes. The unit contains the materials, spare parts, and tools needed to sustain production between resupply opportunities. From printing mission gear to reducing aircraft weight, the X7 FE allows defense personnel to manufacture components in disconnected environments, bypassing traditional logistics and supporting critical operations directly at the edge.

SPEE3D – XSPEE3D

Australia-based SPEE3D has pioneered cold spray metal additive manufacturing, which uses kinetic energy to create metal parts using powders shot at hypersonic speed.

The company’s expeditionary system, XSPEE3D, is containerized, mobile, and designed to withstand harsh conditions while printing cast-equivalent aluminum parts at unprecedented speed. While others have experimented, SPEE3D is the only company offering a field-deployable system for additive manufacturing of metal parts.

SPEE3D’s original WarpSPEE3D system was the first metal 3D printer in the world to successfully manufacture metal parts on a US Naval ship during the US Navy’s REPTX trial. Then, the company unveiled XSPEE3D as the world’s fastest all-in-one containerized metal 3D printer.

XSPEE3D was developed specifically for the military, based on the company’s experiences with the Australian Army during their world-first metal 3D printing field trials in 2020 and 2021. SPEE3D’s partnership with the British Army during the U.S. Army’s Project Convergence 2022 showcased its battlefield utility. Later, In the California desert, parts like CVRT drive sprockets, HEMTT shackles, and specialist tools for the M109 howitzer were designed and printed in under a day. During the joint exercise, SPEE3D and the British Army collaborated on creating dozens of applications for various armored vehicles over the campaign’s two weeks.

More recently, SPEE3D participated in the U.S. Army Combat Capabilities Development Command (DEVCOM) Army Research Laboratory (ARL) advanced manufacturing demonstration at the University of Tennessee Knoxville. The exercise saw a soldier without prior experience successfully print and install a transmission mount for a Bradley Fighting Vehicle, restoring it to full operation.

By demonstrating that key vehicle and weapons components can be produced in a matter of hours on the battlefield—often in temperatures over 100°F or during heavy rainfall—SPEE3D has validated its cold spray approach as a viable, scalable solution for military supply chain resilience.

Xerion – Fusion Factory XS

The Xerion Fusion Factory XS is a complete production line that fits into highly protective, extra rugged 19“ cases that can be easily transported on trucks or ships. It provides an efficient tool for quickly producing spare parts on demand using various materials. The system leverages Xerion’s bound metal filament extrusion 3D printer, one of the first to enter the market, and third-party bound metal filament steel or other materials such as those offered by Nanoe and, in the past, Forward AM. The system also integrates Xerion’s furnace, which is the company’s core business. The PELICAN CLASSIC 19″ RACKTM 21U is an extra-rugged edition designed for high-performance applications. It measures 686 mm in width, 1,029 mm in depth, and 1,181 mm in height. It is engineered for super-safe oxalic acid handling and includes a sinter furnace with a maximum temperature of 1,550°C. The system supports atmospheric conditions, including N2, N2/H2, Argon, and Ar/H2. The specialized multi-atmosphere sintering process effectively burns out binder residues and fuses metal particles into a solid mass at high temperatures.

Xerion’s Fusion Factory XS also includes the debinding station. Thus, the Xerions Fusion Factory XS has been successfully tested for deployable metal spare parts production by several armed forces, including organizations such as the Finnish National Defense, the Sweden Armed Forces Technical School, Bundeswehr (German Federal Defense), Ministère des armées (France’s Ministry of Defense), the Faculty of Military Technologies University of Defence (Czech Republic), and the US Department of Defense.

BigRep IPSO 105

BigRep, a global leader in industrial large-format 3D printing, showcased its newest high-performance system, the BigRep IPSO 105 3D printer, at DEFEA 2025 in Athens. Engineered specifically for demanding defense and tactical applications, the IPSO 105 is designed to bring industrial-scale 3D printing capabilities directly to the point of need.

Built for performance in tough environments, the IPSO 105 3D printer features a temperature-controlled build chamber and high-temperature dual extruders capable of reaching up to 450 °C. The system supports a wide range of engineering-grade materials, including polycarbonate (PC), nylon (PA), PEKK, carbon fiber-reinforced polymers, and flexible TPU, making it well-suited for producing large, functional parts that standard desktop 3D printers cannot handle.

Firestorm Labs – xCell Mobile Factory

Unlike general-purpose 3D printing companies, Firestorm Labs is a well-funded startup built entirely around military deployment. Their flagship product, the xCell, is a mobile manufacturing unit capable of directly producing drone components and spare parts in-theater. Housed in two 20-foot containers, xCell integrates additive manufacturing (likely HP’s MultiJet Fusion end-to-end solution), automation, and robotic assembly for rapid production at the edge.

Originally developed to manufacture Firestorm’s Tempest drones—modular, multi-mission UAVs—the xCell system has proven its adaptability. Most recently, during the 2025 Joint Interagency Field Experimentation (JIFX), it produced drone airframes and replacement parts in severe weather conditions.

During the JIFX field event, Aurelius Systems demonstrated its Laser Weapon System (LWS) by successfully shooting down Group 1 quadcopters at distances up to 110 meters using near-infrared fiber lasers. The system identified, tracked, and engaged drones in sentry mode, marking a milestone for the small defense startup. Chariot Defense replaced the traditional fossil fuel generators powering the LWS with its compact, low-signature, high-voltage battery system, which powered the laser and had enough reserve energy for 1,000 additional shots to enhance portability and reduce thermal and acoustic signatures.

Meanwhile, Firestorm Labs deployed its xCell mobile additive manufacturing system at McMillan Airfield. Housed in two 20-foot containers, xCell produced modular drone parts for the Tempest UAS and other potential systems, addressing logistical challenges in contested environments. The Tempest drone features modular payloads, interchangeable engines, and ranges of up to 675 miles. Chariot Defense also supported Firestorm’s xCell by powering part of the drone assembly operation, showcasing collaboration and the growing role of quiet, efficient power sources and mobile manufacturing in modern battlefield logistics.

Craitor – FieldFab

Craitor is another defense-first company developing the FieldFab 3D printer, directly collaborating with the U.S. Marine Corps and Army through a Cooperative Research and Development Agreement (CRADA). FieldFab is built to MIL-STD-810H standards and has survived deployment in extreme conditions—from Arctic cold to tropical monsoons.

Compatible with high-temperature polymers and engineered for ease of use, FieldFab is designed to be operated by soldiers with just a few hours of training. Over 25 field deployments have seen it used to print spare parts and small UAS components during missions across Alaska, Okinawa, and Hawaii. Its modular design, weatherproof casing, and off-grid power compatibility make it an ideal tool for rapid, in-situ repairs and low-volume manufacturing.

By embedding with military units and co-developing alongside warfighters, Craitor has ensured its solution addresses the nuanced, high-stakes challenges of frontline logistics.

Together, these four companies represent the leading edge of battlefield additive manufacturing. Whether through the rugged versatility of Markforged’s composites, the raw speed of SPEE3D’s cold spray metal, the autonomy of Firestorm’s drone-focused xCell, or Craitor’s polymer-based field repairs, they are all working toward a common goal: enabling mission-critical production where it matters most—at the edge.

*This article has been updated from its original version to add Xerion and the Xerion Fusion Factory XS, which was not initially included. It was later updated to also include the Big Rep IPSO 105 system.