Newport News Shipbuilding Achieves Milestone with First 3D-Printed Manifold for USS Enterprise

Shipbuilding, like other major industries, continues to explore the potential of additive manufacturing technology, commonly known as 3D printing, to enhance construction and repair processes. Recently, HII announced that its Newport News Shipbuilding facility has successfully printed and installed the first-ever manifold using this technology for the upcoming aircraft carrier USS Enterprise.

Dave Bolcar, the vice president of engineering and design at NNS, stated:

“What started as a proof of concept quickly turned into a tangible result that is making a meaningful difference to improve efficiencies in shipbuilding. The benefits of this innovation will extend well beyond Enterprise (CVN 80), as we incorporate our expertise in additive manufacturing into the fundamentals of shipbuilding.”

The valve manifold assembly, which allows for the distribution of a single source of fluid to multiple points on the ship, has been installed in the pump room of the Gerald R. Ford-class aircraft carrier Enterprise. This assembly measures approximately 5 feet in length and weighs 1 000 pounds. Newport News collaborated with DM3D Technology to manufacture the manifold body.

The shipyard views this achievement as another demonstration of its commitment to leveraging additive manufacturing in construction. Similar manifolds are planned for the next carrier in the class, Doris Miller (CVN 81), which will also utilize additive manufacturing instead of traditional casting methods.

HII reports that this latest advancement in additive manufacturing builds on Newport News’ previous certification and approval as a supplier of additive manufacturing components for Naval Sea Systems (NAVSEA) platforms. To date, the shipyard has produced over 55 additively manufactured parts that have been installed on both new vessels and those currently in the fleet, with plans to install more than 200 additional parts this year.

Newport News emphasizes that the use of certified 3D-printed parts has the potential to accelerate the construction and delivery of vessels to the US Navy. This technology allows for reduced lead times and improved manufacturing quality for critical components.

Four years ago, the US Navy began to accelerate the adoption of 3D printing after installing its first-ever 3D part in 2018. Initially used for critical and obsolete parts, the Navy moved in 2022 to install printers and test them on deployed vessels. The USS Essex, a Wasp-class Landing Helicopter Dock, was the first to install a printer in July 2022. As the technology has proven effective, the Navy is now prepared to accept parts produced using this technology on its most advanced vessels, including the newest carriers.