Operationalizing Metal Additive Manufacturing for Expeditionary Employment by the United States Marine Corps

Abstract

This thesis examines four metal additive manufacturing (AM) processes and assesses their suitability for ground expeditionary operations by the United States Marine Corps (USMC) through a cost effectiveness analysis. Metal AM, while in use in industrial applications for many years, has reached a maturity level where expeditionary employment is viable. However, a knowledge gap exists in understanding which technology is best suited for deployed operations. Concurrent with metal AM technology advancements, the USMC is conducting a significant reorganization and refocus on supporting distributed naval operations against peer threats, requiring new sustainment concepts. This thesis examines the cost effectiveness of each AM process to enable a reduced logistics footprint through production of parts as far forward and close to the point of need as possible, limiting supply stockpile size and minimizing transportation costs. Using AM process characteristics, printer cost data, and total quantity of parts produced over a five-year period, the cost-effectiveness (CE) ratio determined for each candidate process supports the recommendation of a hybrid AM process as the most cost-effective alternative.