PATUXENT RIVER, Md., May 13, 2025 — Two U.S. Army soldiers from the 10th Mountain Division recently applied additive manufacturing skills learned at the Naval Aviation School for Additive Manufacturing (NASAM) to address equipment shortages during a Middle East deployment. Specialist James Martin and Specialist Harry Vo, part of Bravo Company, 10th Brigade Support Battalion, 1st Brigade Combat Team, designed and 3D printed a critical antenna mount for mine-resistant ambush protected vehicles while supporting Combined Joint Task Force – Operation Inherent Resolve.
Task Force Wolverine faced challenges with their Starshield communications system due to the lack of an antenna mount. Martin and Vo created a 3D-printed mounting bracket using acrylonitrile styrene acrylate, a durable polymer resistant to UV rays and heat. The bracket ensured optimal antenna positioning, protected the equipment, and maintained the vehicle’s emergency hatch and turret functionality. “This successful cross-service training demonstrates how AM capabilities can provide immediate solutions to operational challenges across the Department of Defense,” said Theodore Gronda, NAVAIR’s additive manufacturing program manager. “When supply chains can’t deliver, AM delivers.”
The soldiers’ solution reduced manufacturing time and costs compared to traditional methods. Although their NASAM training did not cover the specific material used, the six-week program provided foundational knowledge that enabled them to adapt to new systems and materials. “AM’s mission is to improve operational readiness and lethality,” said Capt. Alexander Peabody, senior fleet liaison for NAVAIR AM. “The reality is that even during peacetime, supply chain disruptions necessitate the ability to reverse engineer or redesign components to maintain the operational capability of ships and aircraft.”
NASAM, based at the Institute for Advanced Learning and Research in Danville, Virginia, primarily trains Navy and Marine Corps personnel but occasionally includes other branches. Launched with a pilot cohort of 12 students in February 2024, the program equips maintenance personnel to produce parts on-site, addressing supply chain gaps. The school focuses on skills to design and print components critical to operational readiness, particularly in remote or deployed environments.
Martin and Vo’s work highlights the growing role of additive manufacturing in military operations. By producing parts on demand, they ensured Task Force Wolverine maintained communication capabilities without waiting for traditional supply chains. The success underscores NASAM’s impact in fostering cross-service collaboration, enabling soldiers, sailors, and marines to solve real-time challenges with innovative technologies.
The Naval Air Systems Command, headquartered in Patuxent River, oversees NASAM as part of its broader mission to advance aviation technologies. Additive manufacturing has become a priority for the Department of Defense, with programs like NASAM bridging gaps in logistics and enhancing mission flexibility. As supply chain disruptions persist, the ability to produce parts on-site remains vital to maintaining equipment functionality in high-stakes environments.
