This marks the first time a copper-nickel part produced through additive manufacturing has been welded and used on an operational submarine at a public naval shipyard.

The push to accelerate adoption of additive manufacturing across the submarine fleet stemmed from leadership direction within Submarine Forces. Engineers at Portsmouth Naval Shipyard identified an opportunity to use this technology to meet a specific operational requirement for USS Washington.

To execute the effort, the shipyard worked closely with partners across the maritime industrial base to source the 3D-printed part and process it through inspection and certification channels.

The project required coordination across multiple technical teams. The component underwent extensive testing to ensure it met all performance and safety standards, while specialists simultaneously developed and validated a new welding process tailored to the material.

Shipyard leadership emphasized that the accomplishment reflects strong collaboration and innovation across the workforce, with teams working together to deliver a technically complex solution safely and effectively.

The successful use of a welded, additively manufactured part on a nuclear-powered submarine supports broader Navy priorities around modernization, industrial capability, and deckplate-driven innovation.

Leaders within the submarine force highlighted the effort as an important advancement, noting that additive manufacturing can enhance readiness by improving part availability and reducing delays.

Key Highlights

• First welded 3D-printed metal component deployed on a U.S. Navy submarine
• Part type: copper-nickel flange
• Installed on USS Washington (SSN 787)
• Demonstrates real-world use of additive manufacturing in naval operations
• Involved extensive testing, certification, and cross-functional collaboration

Why It Matters

This development highlights how additive manufacturing can improve fleet sustainment by enabling faster production of critical components and reducing dependency on traditional supply chains. It supports increased operational readiness and long-term efficiency.

About Portsmouth Naval Shipyard

Portsmouth Naval Shipyard, located in Kittery, Maine, focuses on the maintenance, overhaul, and modernization of Los Angeles- and Virginia-class submarines. The shipyard plays a key role in advancing innovation and sustaining the Navy’s submarine fleet.