INDIAN HEAD, Md. — A harrowing experience in Afghanistan more than a decade ago continues to inspire innovation at the Naval Surface Warfare Center Indian Head Division (NSWC IHD) in Maryland. The incident, involving a Navy explosives ordnance disposal (EOD) technician grappling with an unexploded MK-82 bomb, left an indelible mark on Russ Maines, now Test and Evaluation Division Director at NSWC IHD.
During the mission, the technician was tasked with locating and destroying unexploded ordnance in a hostile village. When a 500-pound MK-82 bomb dropped by air support failed to detonate, the enemy threat remained. Improvising under fire, the technician used road flares to neutralize the bomb and prevent it from falling into enemy hands. While the mission succeeded, the dangers underscored the need for innovation in munitions manufacturing.
Maines first learned of the story in 2014 when he hired the technician at Sandia National Laboratories. The experience reinforced his determination to revolutionize bomb-making processes, moving beyond conventional methods like casting, forging, or pressing metals. “That story was a turning point,” Maines said. “It highlighted the need for faster, safer, and more reliable solutions.”
3D Printing: Transforming Weapons Manufacturing
At NSWC IHD, Maines has spearheaded efforts to incorporate 3D printing into munitions production, aiming to create a scalable, cost-effective, and efficient process. “Digitally transforming weapons manufacturing will create new Department of Defense [DoD] pipelines that strengthen supply chains,” Maines explained. “And Indian Head is uniquely positioned to lead this effort as the Navy’s only publicly funded arsenal.”
Maines and his team recently conducted a groundbreaking test at Fort Walker, Virginia, involving a 3D-printed cross-section of a general-purpose bomb. The item, developed by Oak Ridge National Laboratory for the Defense Threat Reduction Agency, underwent arena tests to assess its lethality. NSWC IHD engineers, part of the Detonation and Combustion Technology Branch, hand-packed the bomb with C4, staged the test area, and captured data using high-speed cameras and sensors.
The initial results were promising. Maines noted, “The data says there’s no reason to stop. While adjustments are needed, the potential benefits are clear.” Among those benefits: reduced production costs—up to three times cheaper than traditional methods at low-rate production—and unexpected performance improvements, including enhanced blast physics and fragmentation.
A Strategic Imperative
The timing of these advancements is critical. Global conflicts have spurred unprecedented demand for munitions, placing strain on supply chains and emphasizing the need for innovative approaches. NSWC IHD Technical Director Ashley Johnson highlighted the importance of leveraging technology to address these challenges.
“Innovation is not optional,” Johnson said. “Our role is to integrate state-of-the-art technology to ensure readiness and dominance.”
Chief of Naval Operations Adm. Lisa Franchetti echoed this perspective, emphasizing adaptability in modern warfare. “Cheaper, more accessible technology is driving asymmetric capabilities, offering profound implications for the future of warfare,” Franchetti said. “We’ve learned a great deal about how innovations like 3D printing can redefine the battlefield.”
Building a Future of Efficiency
As testing continues, Maines and his team remain committed to refining 3D-printed bomb designs, aligning their efforts with the Navy’s broader strategy to modernize capabilities and enhance readiness. “We’re not just making explosives; we’re solving problems,” Maines said. “Our mission is to deliver solutions that are faster, cheaper, and better for our warfighters and taxpayers alike.”
NSWC IHD’s work represents a crucial step forward in addressing the challenges of modern conflict. By integrating advanced manufacturing methods, the command aims to strengthen supply chains, reduce costs, and improve the effectiveness of its munitions—an effort that reflects the evolving needs of the U.S. Navy and the Department of Defense.
