age footstock/Alamy Stock Photo/KNEFNC Stock age footstock/Alamy A hybrid laser machine tool for additive manufacturing (AM). This researcher is working on a 3D printing machine for industry, which is able to create large metal parts from scratch and to finish them with great precision. MILITARY SCIENCE AND TECHNOLOGY The Implications of Additive Manufacturing on Canadian Armed Forces Operational Functions by Christopher Bayley and Michael Kopac Christopher Bayley is a Senior Defence Scientist with Defence constitutes one of the seven supply chain scenarios that favor Research & Development Canada (DRDC). He is currently leading AM. Other factors which will tend towards the use of AM to efforts within the Naval Platforms portfolio in parts-on-demand, manufacture parts have been identified as: circumventing long has advised the office of Chief Scientist on the disruptive aspect of lead-times, high inventory costs, reducing the reliance from a Additive Manufacturing, and briefed the Army Science & Technology single supplier, manufacturing close to market in order to reduce board on military specific applications of this technology. shipping costs or circumvent import/export restrictions, and enabling increased functionality.2 Michael Kopac is an Engineering Technologist with DRDC who specializes in polymer chemistry. The range of materials which are amenable to this manufacturing process are as diverse as its applications. They range from biologi- Introduction cal materials, polymers, cement, metals, and combinations thereof, and form products which stretch from microns to meters. The only dditive Manufacturing (AM), commonly referred restriction is that the material needs to be placed into position and to as 3D Printing, is a collection of manufactur- either fused, or solidified with the underlying material. The process ing techniques that create objects by depositing may be used alone, in which case, an idea can go directly from a 3D layers of material based upon digital models. It design file to a finished part or product (direct-digital manufacturing), is an emerged manufacturing process that stems or may constitute a stage within a larger manufacturing process. Aback to the development of stereo-lithography, but it has seen a resurgence of international interest following the expiration of According to Dr. John Burrow, Deputy Assistant Secretary of some key patents in 2009. According to the Wohlers Associates, the US Navy, few manufacturing processes touch so many aspects an industry analyst, AM industries grew over 25% in 2015.1 Part of the military enterprise extending from the design, procurement, of this growth includes applications within Defence in which logistics, sustainment, and care of the wounded soldier. AM is comparatively small production runs and high development costs included on the CAF “Future Security Environment 2013-2040” Canadian Military Journal • Vol. 18, No. 3, Summer 2018 47 technologies watch list, and is included on the list of emerging Sustain disruptive technologies [an innovation that significantly alters or displaces an established technology, or creates an entirely new f all potential concepts of employment for AM, none industry – Ed.] by Innovation, Science and Economic Development O have been as widely embraced as sustainment. Within Canada, while advanced manufacturing, of which AM is a part, the realm of sustainment, potential applications include is specifically cited in the Federal 2017 Budget as an area of tar- parts-on demand, free-form manufacturing of infrastructure, geted innovation. However, despite the frequency of references to and enabling customized health care solutions. AM has been AM being disruptive, and of particular interest to Defence, identified as a solution to resolve the spare parts inventory CAF leadership in defining potential applications is lacking.3 problem as the logistics associated with spare parts is time consuming, expensive and complicated. Already the use of AM The intent of this article is to highlight the breadth of to either shorten or simplify the logistics tail is one of the most application that AM could affect the Canadian Armed Forces (CAF) prevalent applications for AM. This is particularly pertinent for Operational Functions. Concepts of employment in which AM ageing platforms in which there is no longer the availability provides an enabling capability are discussed through illustrative of Original Equipment Manufactured parts. Remaking of the vignettes which highlight how AM technologies are being used in parts via conventional forging, casting, and machining can Defence applications around the world. It is hoped that by iden- often take up to two years, not including the additional time tifying the breadth of potential applications that AM is capable required for the qualification of the part. In addition to short of disrupting, a tipping-point is reached and the requirement to circuiting long-lead times, AM may also be considered for invest in AM innovations will be realized. parts with high production costs due to complex geometries, high fixed costs (i.e., tooling), or those that are produced in AM within the Canadian Army Operational Functions low volumes.5 he 2014 Emerging Disruptive Technology workshop AM need not be restricted to the manufacturing of small T sponsored by the Canadian Army Land Warfare Centre parts, but is equally capable of constructing infrastructure, includ- (CALWC) identified how AM could influence the Canadian ing the building of base camps, and humanitarian efforts, or Armed Forces (CAF) operational functions of Command, enclosing contaminated areas with limited exposure to personnel. Sense, Act, Shield, Sustain and Generate. Figure 1 illustrates Commercially, AM in this marketplace is termed construction the results of the consultative process that involved the input 3D printing, and it generally utilizes a fiber reinforced fast dry- from subject matter experts and Canadian Army (CA) per- ing Portland cement and precision gantry to additively deposit sonnel on the perceived impact that AM will have over the layers of cement. Its disruptive potential is that it can be used to intermediate (5-10 years) and longer horizon (10+ years). rapidly construct large concrete structures without the need for While the CALWC study focused upon CA operational forms, either directly at the construction site or as pre-fabricated functions, the results are largely Service independent. slabs which are subsequently transported and assembled on-site. GENERATE COMMAND Command and Control Network Force Projection 80 Planning and Decision Support System Organizational Force Generating Structures 70 JIMP Connectivity 60 Health Services System 50 Ground Sensor Network 40 Airborne and Administration 30 System Strategic Sensor 20 Network SENSE SUSTAIN 10 Intelligence System Materiel and 0 Distribution System Land Equipment Fires System H2 (+5-10 Years) Protection from H3 (+10 Years) Manoeuvre Psychological Threats ACT CBRND Information Operations SHIELD Explosive Hazard Avoidance Protection from Fires A. Auger, DRDC-RDDC-2105-C118, 2015 DRDC-RDDC-2105-C118, Auger, A. GBAMD Figure 1 – ImpactNote of AM to across Accurate: the CAF operational The PDF functions. has been4 provided in case it is best for reproduction; however French text would need to be inserted. Excel spreadsheet (Chart 2) is 48 the same figure and provided in Canadianboth official Military languages. Journal • Vol. 18, No. 3, Summer 2018 Costs associated with the construction 3D printing of a disaster can be tailored with pigmentation, cellular gradations necessary relief structure are comparable with traditional shelters fabricated to account for wound depth, and macroscale ridges. To date, from timber and steel, with the potential advantage of improved bio-printing is still unable to fully replicate natural skin in terms durability and longevity. Current efforts within the US Army of its morphological structure, biochemical, and physiological Research Laboratory include the fabrication of infrastructure from properties. However, some simple skins have been printed with natively-acquired feedstocks (i.e. printing buildings using indig- limited functionality in in-vivo studies.9 Another biomedical appli- enous materials), which parallel the commercial efforts, such as cation is orthotic implants, with a key driver being the potential D-Shape, which utilizes a binder to join particles of sand together for bespoke implants that match the requirements of wounded forming an artificial marble, and the US National Aeronautics and soldiers. While the field of orthopedic implants is likely well Space Administration (NASA) efforts to use extra-terrestrial mate- served through civilian research, maxillofacial reconstructions rials for lunar structures. Construction 3D printing need not only arising from defence specific injuries are being developed at the consider the direct fabrication of structures, but can also involve US Veterans Affairs and Walter Reed Hospital. In this regard, the printing of building blocks and bricks. Emerging Objects, AM is one of one the technologies enabling the provision of an Architectural research group, has printed irregularly-shaped personalized medicine and the rehabilitation of wounded soldiers.10 hollow blocks that when nested together can resist earthquakes. The earthquake resistance is achieved by allowing each block to Act move independently rather than as monolithic mass, as would be the case for a conventional mortar rectangular wall.