SERMC 3D prints cost-saving mission-critical components

Southeast Regional Maintenance Center (SERMC) is using 3D printing to rapidly develop mission-critical components – saving time and money and enabling the rethinking of traditional maintenance and logistics.

When a chilled water pump cooling rotor used on an Arleigh Burke-class guided missile destroyer needed replacement, the team didn’t have to wait weeks or months for a conventional order. The six-blade part, not available to purchase separately in the Navy supply system, typically requires the purchase of an entirely new pump, at a significant cost, to correct the deficiency. Instead, the team was able to manufacture four progressively refined prototypes over two weeks – rapidly developing a final blueprint ready for printing, testing, and installation.

“Sailors at SERMC are always looking for new applications for 3D printing to expand our capabilities and save time, resources, and money,” said Capt. Kiah Rahming, SERMC’s commanding officer. “This effort is a testament to the ingenuity and drive of our team.”

“We started by reverse engineering the original aluminum piece to create a prototype using a low-cost polymer,” said Chief Machinist’s Mate Nicholas Heinrich, SERMC’s Additive Manufacturing coordinator. “The original part fits very snugly to the shaft, so after a satisfactory fitment check, we coordinated with Fleet Readiness Center Southeast (FRCSE) Detachment Mayport to identify the best material for the final part.”

That final part was produced using an aerospace-grade thermoplastic known for its strength, heat resistance, and flame retardancy. Manufactured using an industrial-grade 3D printer at FRCSE, the blade offers comparable strength to aluminum, but at a fraction of the weight and cost. After a satisfactory operational test, the pump was certified in-house and installed aboard the ship.

The cost savings from SERMC’s 3D printing initiative are substantial. A prototype blade was produced for just $17.63, while the final blade cost only $131.21. In contrast, replacing the entire motor through conventional methods would have cost $316,544.16. This innovative approach resulted in an estimated cost avoidance of $316,412.95 for each blade produced with minimal downtime.

“This manufacturing technique allows our Sailors to disassemble the housing and put the part back together with a superior product,” said Rahming. “When you start comparing the price differentials, they’re substantial. Additive manufacturing is fundamentally changing how we think, how we do business, and how we support the warfighter.”

These cooling pump rotors are installed on every type of ship in the Fleet. The newly printed part has already been tested for operation, certified, and installed aboard a destroyer, demonstrating the operational potential for additive manufacturing within the Fleet.

SERMC’s growing innovation program continues to explore applications of 3D printing that support the full program lifecycle, from early design to testing, training, and sustainment.