NAVSEA advances motion simulation platform for 3D printing at sea

The Johns Hopkins University Applied Physics Laboratory (APL) and GKN Aerospace have developed a motion simulation platform designed to replicate the dynamic conditions of a ship at sea.

The key objective of the platform is to enable additive manufacturing aboard US Navy vessels – the project is being funded by the Naval Sea Systems Command’s (NAVSEA) Technology Office (NAVSEA 05T), in support of the Navy’s Afloat Additive Manufacturing Program.

The core challenge the team set out to solve was how constant shipboard movement caused by waves and maneuvering affects the quality and structural integrity of parts that are 3D printed at sea. 

Rather than mounting an industrial-grade printer on a motion platform, which the teams determined was impractical given the size and fragility of such equipment, they developed an approach that synchronizes movement between the print head and the substrate to simulate sea conditions. One of the systems under evaluation was a Haas TM 1 CNC mill paired with a Meltio laser wire print head, which weighs up to 2,540kg.

“Additive manufacturing at sea could fundamentally change how the Navy maintains and sustains its fleet,” stated James Borghardt, APL’s Maritime Expeditionary Logistics program manager. “With a proven history of industry collaboration and a continued commitment to partnership, APL is positioned to accelerate this future by uniting commercial manufacturing expertise with our applied research to deliver mission-ready capabilities.”

Testing under simulated sea states

To assess system performance, the team conducted controlled test prints using triple line trace patterns on metal coupons, printing six-inch test blocks under motion profiles representing both calm and rough sea conditions.

“We approached this challenge by combining our understanding of additive materials behavior with practical experience in manufacturing process control,” explained David Bond, Head of Engineering and Technology at GKN Aerospace.

“That integration has been key to developing a solution that can print quality representative samples under the motion conditions expected in shipboard environments.”

Bianca Sciandra, project manager and a metallic materials researcher at APL, described the significance of the data gathered. “This effort is giving us the data we need to move from concept to capability,” she said. “We’re now able to quantify how motion influences build integrity and use that insight to refine system controls, bringing us closer to producing critical, mission-relevant parts directly aboard ships.”

Building on prior fleet deployments

The work extended APL’s existing contributions to NAVSEA’s afloat program. In 2023, APL supported the installation of the Navy’s first hybrid metal 3D printer aboard the USS Bataan (LHD 5) and subsequently assisted sailors in producing a replacement part at sea.

“The USS Bataan deployment proved that additive manufacturing can work at sea,” said Michael Presley, APL additive manufacturing engineer and lead on the Navy collaboration. 

“Now, we’re taking the next step, shifting from noncritical parts to mission-essential components like valve housings and structural mounts. This capability enhances the fleet’s ability to maintain readiness and adapt in real time, even in challenging environments.”