By now, kind of everybody within the AM trade appears to understand the central function in accelerating AM adoption performed by the protection sector typically, and the U.S. army specifically. Nonetheless, as was highlighted on this latest 3DPrint.com interview with Mike Shepard of 3D Programs Company, there nonetheless aren’t that many true broad-based specialists in AM for the army.
Tali Rosman is one such professional. The onetime CEO of Xerox’s Elem Additive, which was finally acquired ADDiTEC, Rosman has written quite a lot of studies for Additive Manufacturing Analysis, together with a number of research particularly on the AM marketplace for protection. Her opinion is sought out by AM firms and commerce associations all over the world.
Tali Rosman moderating a panel at AMS 2025. Picture courtesy of Sarah Saunders/3DPrint.com
At Additive Manufacturing Methods 2026 (February 24-26 in New York Metropolis), you possibly can see Tali moderating a panel on “The Way forward for Steel Elements for Aerospace & Protection,” as she and the panelists dive in to what appears to be like like it should stay one of many key demand drivers for the AM trade for years to return. In the event you haven’t registered for the occasion but, it is a excellent time to take action — the usual registration deadline expires December tenth.
To get an concept of what sorts of themes shall be mentioned on the panel, and through the Aerospace and Protection session as a complete, Tali shared her precious perception on some necessary subjects at present animating the world of army AM.
Matt Kremenetsky: For at the least the final 12 months or so, everybody targeted on AM for protection has been paying essentially the most consideration to the Navy. Which purposes past maritime are you most targeted on?
Tali Rosman: The Navy has rightfully taken the highlight for its work in shipboard AM and the SIB program, however AM is getting used compellingly throughout the DoW. On the Military facet, I’m equally enthusiastic about each expeditionary and floor logistics purposes, together with:
- Ahead-deployed half manufacturing for automobile restore, unmanned techniques, or base infrastructure — particularly in contested logistics environments.
- Half restore at each the tactical and depot ranges to scale back lengthy lead occasions and enhance readiness.
- Additive building, reminiscent of 3DP concrete for barracks, partitions, and shelters — which is quietly transferring from pilot to functionality.
The Air Power, in the meantime, has a number of attention-grabbing use instances in MRO and sustainment, spanning AM applied sciences. We’re additionally seeing rising cross-branch momentum in warfighter medical purposes — from surgical fashions to customized orthotics — the place AM’s capability to personalize and ship rapidly is a transparent differentiator.
MK: How is what’s taking place in protection a mannequin that may be utilized to profitable AM adoption in different sectors?
TR: Protection has turn out to be a real-world check mattress for de-risking AM at scale — taking applied sciences out of the lab and into among the most demanding environments. That’s precious far past the army. Specifically:
- Qualification pathways: The structured, rigorous half vetting in protection can inform frameworks for aerospace, power, and different demanding industries.
- Distributed manufacturing fashions: What the DoW is piloting throughout depots, bases, and afloat ships can function a blueprint for distant or multi-site industrial operations.
- Public-private collaboration: Packages like DIU present how stakeholders with very completely different timelines can nonetheless align on shared objectives — a precious lesson for any massive OEM attempting to accomplice with AM startups.
Backside line: protection isn’t simply an early adopter — it’s constructing the playbook for scaling AM beneath real-world constraints, and that playbook interprets on to different high-consequence sectors.
Marines from seventh Engineer Assist Battalion together with engineers from the U.S. Military Corps of Engineers Development Engineering Analysis Laboratory pose with a concrete bunker throughout a 3D concrete printing train. Photograph through U.S. Marines/Workers Sgt. Michael Smith, seventh ESB.
MK: As somebody who has labored with the US army, what’s some recommendation you can provide firms who’re hoping to enter the federal government market?
TR: Breaking into the DoW isn’t nearly promoting a product — it’s about studying to function inside a singular procurement and decision-making ecosystem. My prime items of recommendation:
Begin small however strategic — a profitable prototype through an SBIR or a DIU pilot could be your wedge into a lot bigger alternatives. We’ve seen success when applications give innovators a transparent path into sustainment — just like the Navy’s CRADA with FormAlloy at FRCSW, which turned a pilot restore course of right into a funded functionality. Streamlining requirements throughout branches would multiply these sorts of wins.
Get fluent in “DoW-speak” — align your worth proposition to not “higher printing,” however to operational readiness, price avoidance, or logistics discount.
Herald somebody who’s walked the halls — hiring or partnering with a former DoW insider dramatically accelerates the training curve, from navigating procurement guidelines to discovering the suitable champions. For instance, in 2024 Nikon appointed Admiral Mike Mullen (Ret., USN), former Chairman of the Joint Chiefs of Workers, as a Strategic Advisor — and not too long ago introduced a partnership with the U.S. Navy to broaden maritime AM.
Be affected person however persistent — timelines are lengthy, budgets are cyclical, and success comes from constantly aligning with shifting program priorities.
MK: As army AM adoption steadily expands, do you see cybersecurity as an more and more necessary challenge?
TR: Completely — and I’d really broaden it to incorporate each cybersecurity and sourcing integrity. As we digitize extra of the protection provide chain, the assault floor is getting wider — not simply by way of information, but in addition by way of the machines we’re counting on.
- On the cyber facet, AM introduces actual dangers: design information, course of parameters, monitoring information — they’ll all be tampered with in methods which are laborious to detect however catastrophic in the event that they fail within the area.
- On the availability chain facet, we’re nonetheless seeing firms label issues as “Made within the USA” whereas quietly reselling imported machines — together with techniques with unknown firmware and connectivity danger. It checks the compliance field however misses the purpose solely.
Backside line: in AM, the machine is the manufacturing unit, and if we’re severe about nationwide safety, we are able to’t deal with the digital and bodily layers individually. It’s not nearly securing information — it’s about securing the complete stack: {hardware}, software program, sourcing, and the ecosystem round it. Securing the file is desk stakes; securing the manufacturing unit is the true problem.
3D printed metallic components from Trident Warrior 25. This helicopter hangar door sensor bracket was printed by NAVSEA Warfare Facilities/Naval Floor Warfare Heart Carderock Division (NSWCCD) and put in on a DDG. Picture courtesy of FLEETWERX.
MK: In the event you had the power to alter one factor about how protection procurement works within the context of AM, what would it not be?
TR: Just one factor? I’ve a couple of in thoughts, however to select one, I’d begin with streamlining the qualification and procurement requirements throughout branches. In the present day, you possibly can qualify a component with one service and begin again at sq. one with one other — even when the fabric and utility are practically an identical.
This fragmentation slows innovation and frustrates suppliers. A extra unified method would speed up adoption and scale back redundant price and energy.
MK: Do you see AM for the US army transferring extra within the path of 1 enterprise surroundings that works throughout the entire division, or do you suppose the army’s AM exercise will at all times be primarily siloed into every department/company?
TR: Realistically, some siloing is inevitable, given the distinctive mission units and platforms of every department. However I do suppose we’re seeing momentum towards a extra interoperable and linked AM ecosystem:
- Shared repositories for certified components.
- Widespread supplies libraries and testing protocols.
- Cross-branch pilots and consortiums.
Even when we are able to’t keep away from silos solely, we should always be certain that data, information, and components can move between them — particularly in joint operations or contested logistics eventualities. We don’t want full uniformity — simply interoperability. That’s what’s going to make AM actually scalable throughout the companies.
In the event you’re fascinated about extra of what Tali thinks concerning the present state of the AM trade, catch her on this episode of Printing Cash. And don’t overlook to register for AMS 2026!
This interview was initially seen in AMS: The Preprint.
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