Using Additive Manufacturing to Mitigate the Risks of Limited Key Ship Components of the Zumwalt-Class Destroyer

Abstract

The purpose of this project was to explore the benefits of using a combination of additive manufacturing (AM), Performance-Based Logistics (PBL), and Open Systems Architecture (OSA) to mitigate the risks of limited key ship components for the Zumwalt-class destroyer (DDG 1000) program. Specifically, this project was focused on current industry's capability for AM and the implementation of AM in the near future. Research was conducted in three phases. First, this research reviewed the problems and challenges within the defense industry. Next, this research reviewed the previous research on intellectual property (IP) concerns with AM (particularly, insourcing versus outsourcing) and the latest AM applications in the marketplace and defense industry. Finally, this research focused on DDG 1000 program documents, including the Acquisition Strategy (AS), the Life-Cycle Sustainment Plan (LCSP), and a Diminishing Manufacturing Sources and Material Shortages (DMSMS) analysis. By conducting a comparison of DDG 51 and DDG 1000 and analyzing an AM arrangement among Airbus, Systemanalyse and Programmentwicklung (SAP), and United Parcel Service (UPS), this research concludes that the government can use AM, with a properly structured PBL arrangement and OSA, to substantially mitigate risks, lower operation and support (O&S) costs, and effectively improve system readiness.