3D Systems Gets Another $9M From the Air Force for Large Metal Prints

Another $9 Million for Large-Scale Metal Printing

3D Systems has been awarded an additional $9 million contract from the U.S. Air Force to continue developing its large-format metal 3D printing system. The award brings total program funding to $27.4 million and extends work the company has been executing since 2023.

The program focuses on building a large-scale metal 3D printer capable of producing flight-critical components. Work will continue at 3D Systems facilities in San Diego, California and Rock Hill, South Carolina.

What the System Is Designed to Do

The system uses laser powder bed fusion to print large, high-temperature metal parts relevant to high-speed flight. Hypersonic platforms, in particular, demand components that can survive extreme heat and stress. Traditional manufacturing methods struggle with the complex geometries these parts require.

3D Systems says the platform is designed to produce flight-relevant metal structures at scale. That last phrase, at scale, matters. A lot of metal 3D printing research stays in the lab. The Air Force contract is explicitly pushing toward production-ready output.

Defense Drives Commercial Spillover

Defense money has a way of accelerating technologies that eventually reach commercial markets. The same logic that applies to GPS and the internet applies here. Large-format metal 3D printing for hypersonic components uses the same underlying processes that could serve aerospace, energy, and heavy industry.

When a manufacturer can print a complex metal bracket or structural component on demand instead of waiting weeks for a supplier, operational flexibility changes. The Air Force needs this for logistics resilience. Commercial buyers need it for cost and lead time.

Why This Round Matters

This is the third contract award in the program. The first phase landed in 2023 at $10.8 million. A second phase followed in 2025 at $7.65 million. This latest $9 million award reflects what Dr. Michael Shepard, 3D Systems VP of Aerospace and Defense, described as continued Air Force confidence in the technology development path.

The completion target remains September 2027. If the system hits its milestones, it will represent one of the most mature large-format metal AM platforms anywhere. That timeline also puts it in position to influence the next generation of defense and aerospace manufacturing standards.