3D Systems expands US A&D operations amid rising defence AM demand
3D Systems, Rock Hill, South Carolina, USA, has announced significant momentum in its Aerospace & Defense (A&D) business, including robust revenue growth projections, a major US facility expansion, and key technological advancements. These initiatives position the company to capitalise on rising demand for secure, US-based manufacturing in national security and space applications, further supported by recent provisions in the National Defense Authorization Act (NDAA) for Fiscal Year 2026 that restrict foreign-sourced Additive Manufacturing machines for Department of Defense (DoD) programmes, creating additional tailwinds for domestic providers. Complementary global operations continue to support international customers valuing regional production and worldwide expertise—driving sustained revenue growth, margin expansion, and shareholder value.
The A&D business is forecast to have grown over 15% in 2025, accelerating to more than 20% in 2026. Revenue from production AM systems and custom metal parts, core recurring elements of the business, is expected to exceed $35 million in 2026, driven by increasing adoption in high-reliability defence and space programs, with further upside from NDAA-related demand shifts.
After several years of sustained double-digit growth, A&D is reportedly on track to become 3D Systems’ largest and fastest-growing industrial business in 2026, fuelled by rising demand across crewed/uncrewed aircraft, naval platforms, defence systems, rocket propulsion, and satellite systems.
3D Systems is adding up to 80,000 square feet to its Littleton, Colo., facility, enhancing its A&D Application Center of Excellence. This phased investment expands capacity for application development, process qualification, validation, and production-scale manufacturing, supporting accelerated innovation and strengthened domestic supply chain resilience.
The Littleton facility has been selected for certification under the America Makes JAQS-SQ framework. This effort, under the National Center for Defense Manufacturing and Machining, in collaboration with the National Institute for Aviation Research (NIAR) aims to scale defence industrial base capabilities for qualified Additive Manufacturing production, enabling accelerated qualification and deployment of additively manufactured defence components. This leverages the company’s Littleton quality infrastructure established through its medical technology business, where high-performance metal implants, such as titanium implants created on the DMP 350 system, have been manufactured over many years.
The company is progressing on schedule in its multi-phase, $18.5 million US Air Force-sponsored programme to develop next-generation Laser Beam Powder Bed Fusion (PBF-LB) technologies for large format, high-efficiency metal part production. These technologies are essential for the application of metal AM to an expanding range of US defence systems. Key programme milestones remain on track through 2027.
When completed in 2027, 3D Systems will reportedly be the only US provider of a complete, end-to-end metal AM ecosystem entirely onshore for large-frame metal AM machines with over 1 metre print area, encompassing system design, next-generation AM machine manufacturing, and certified metal parts production with advanced application development. This uniquely positions the company to meet growing demand for secure domestic supply chains.
Paralleling the company’s US A&D infrastructure, European operations provide aerospace-focused design and application expertise in Leuven, Belgium (AS9100-certified), and metal printer production in Riom, France, directly supporting European, Korean, Japanese, and other international A&D customers. In addition, the NAMI joint venture in Saudi Arabia, now the Kingdom’s first AS/EN 9100-certified AM provider, is advancing localised A&D solutions, including a collaboration with Lockheed Martin to qualify and manufacture mission-critical components within the Kingdom for global markets.
Dr Jeffrey Graves, president and CEO of 3D Systems, shared, “Aerospace and defence customers worldwide increasingly require a reliable partner that delivers qualified, scalable solutions with speed, security, and supply chain resilience—supported by deep regional expertise and seamless global capabilities.”
“Our Littleton expansion and strategic investments are significantly strengthening our US-based Application Center of Excellence with advanced engineering, qualification-ready platforms, and expanded production capacity—dramatically accelerating the path from prototype to mission-critical deployment and improving outcomes for customers across our US, European, and international operations. Recent US policy developments, including NDAA provisions, provide an additional tailwind that aligns closely with our ongoing domestic investments,” Dr Graves added.
The Littleton expansion is intended to support 3D Systems’ application-specific strategy, combining hardware, materials, software, and expertise across four core value drivers:
- Supply Chain Resilience: Regionalised manufacturing reduces lead times and risks, critical for mission readiness. For example, collaboration with Huntington Ingalls Industries enabled first-to-market copper-nickel (CuNi30) alloy solutions for naval components, reportedly shortening production timelines.
- New Application Development: Through its Application Innovation Group (AIG), 3D Systems co-develops lightweight, consolidated designs with customers. The expanded Littleton Center accelerates qualification and scaling, offering direct engineering collaboration, pilot production, and flexible technology transfer.
- Robust Manufacturing Solutions: 3D Systems’ low-oxygen direct metal AM technology ensures consistent, high-quality output for flight-critical applications. Additionally, in partnership with NIAR and the America Makes Joint Metal Additive Database Definition (JMADD), 3D Systems is working to develop materials allowables on the DMP 350 system that will facilitate additional programmes for challenging end-uses, such as flight, to migrate to 3D Systems platforms.
- Propulsion and Casting Applications: QuickCast Air and additive casting workflows enable complex geometries, rapid iteration, and cost reduction in aviation, space, and energy. Participation in the Penn State-led IMPACT 3.0 programme advances additive integration into casting/forging workflows. These capabilities have delivered significant benefits in advanced rocket propulsion systems, including simplified designs, enhanced performance, and faster production cycles.
Dr Mike Shepard, vice president, aerospace & defence business at 3D Systems, said, “We are prioritising A&D applications where additive manufacturing delivers maximum mission impact—from shipbuilding and advanced defence systems to aviation and space. Our broad technology portfolio and ability to co-develop and efficiently scale critical applications have been key to our success.”
These initiatives reinforce 3D Systems’ leadership in high-stakes additive manufacturing, positioning the company for sustained growth, improved margins, and lasting competitive advantage.
