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Beyond Additive Manufacturing – Hybrid Solutions for Enhanced Resilience in Maritime and Aerospace Operations

19 Nov 2025

The integration of Additive Manufacturing (AM) into military and industrial applications is not merely a technological revolution but also demands new approaches to combine AM with traditional fabrication methods. In collaboration with the German Air Force, Center 23 of the federal armed forces, and the Maritime AM Coordination Hub, we present proven strategies that transcend pure 3D printing techniques. A central example is the development of an adaptive hybrid system for maritime mobile fire alarm systems, where additively manufactured components are combined with electronics, painting and assembly tools to strengthen the resilience of naval units.

The AM-Level System Framework, a structured classification model for evaluating the complexity, capabilities, and integration requirements of AM technologies, highlights how standardization streamlines adoption in temporarily self-sufficient systems (e.g., ships or field environments). Real-world case studies from the German Navy and Air Force demonstrate that AM implementation faces not only technical challenges but also cultural and structural barriers—particularly the necessity of fostering a ""mindset shift"" among stakeholders. 

Further discussion centers on how AM boundaries can be expanded through ""push-pull"" dynamics—from predefined solutions (e.g., standardized military parts) to flexible, demand-driven innovations (e.g., crisis-specific adaptations). Workshops with the European Defense Agency (EDA) exemplify how collaborative AM networks can strengthen international cooperation.

This multidisciplinary dialogue bridges technology, logistics, and organizational development to critically assess the current state of AM adoption while outlining future scenarios for resilient systems in naval and aerospace sectors.

Speakers:
Sascha Hartig, Head of Engineering Principals & Additive Manufacturing, German Navy Support Command
Mr. Benjamin Wolf, Design Engineer, Bundeswehr