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Big Area Additive Manufacturing (BAAM): The Giant Leap in Civilian and Military Production
From shipyards to battlefields, BAAM is redefining large-scale manufacturing with unprecedented speed, flexibility, and cost savings.
Introduction
Additive manufacturing (AM) has revolutionized the way industries produce components, offering unparalleled design flexibility, reduced material waste, and faster production times. Among the various AM techniques, Big Area Additive Manufacturing (BAAM) stands out as a game-changer for large-scale production. Developed by Oak Ridge National Laboratory’s Manufacturing Demonstration Facility (MDF) and Cincinnati Inc., BAAM is designed to print industrial-sized parts quickly and efficiently. This technology uses high-speed extrusion and an open-material architecture, enabling cost-effective production of massive structures using commodity thermoplastic materials.
Beyond its use in traditional manufacturing, BAAM has found significant applications in military and defense, where rapid production, customization, and lightweight materials are crucial. From naval components and military vehicle parts to aerospace applications and mobile logistics solutions, BAAM is helping redefine the way defense systems are developed and deployed.
How BAAM Works
Traditional 3D printing systems are typically constrained by limited build volumes, meaning they can only produce small to medium-sized components. In contrast, Big Area Additive Manufacturing (BAAM) is designed for large-scale production, utilizing a robust machine frame and motion system adapted from laser cutting machines. This adaptation provides greater precision and stability, allowing BAAM to print massive components that conventional printers cannot accommodate.
Another major improvement lies in BAAM’s high-speed extruder and feeding mechanism, which enables the efficient deposition of thermoplastic materials at an accelerated rate. Unlike conventional printers, which build layer by layer at a much slower pace, BAAM significantly reduces build times, making it a practical alternative to traditional manufacturing techniques such as molding or machining.
A key advantage of BAAM is its open material architecture, which supports a wide range of thermoplastics, including carbon-fiber-reinforced polymers (CF ABS). This flexibility allows industries to choose materials based on their specific needs, whether they require lightweight durability, high strength, or heat resistance. Additionally, BAAM’s rapid production speeds mean that large, complex structures can be printed in a fraction of the time compared to both traditional 3D printing and conventional manufacturing methods. This breakthrough makes BAAM particularly valuable for industries like aerospace, automotive, and military applications, where large, strong, and cost-effective components are essential.
BAAM’s Impact on Military and Defense
Big Area Additive Manufacturing is rapidly emerging as a transformative force in military and defense, offering capabilities that go far beyond traditional manufacturing limits. By enabling the rapid production of large, complex, and mission-specific components directly from digital designs, BAAM empowers armed forces to respond faster, adapt more effectively, and operate with greater independence from vulnerable supply chains. Whether it’s producing a fully functional submersible hull in weeks instead of months, fabricating lightweight UAV structures optimized for stealth, or creating customized armor and infrastructure on demand in remote locations, BAAM is reshaping how military assets are designed, built, and deployed. Its speed, cost efficiency, and adaptability make it a strategic game-changer in modern defense operations.
Naval Applications: Submersibles and Surveillance
The demand for maritime surveillance and defense is growing, with navies relying on both manned and unmanned underwater vehicles (UUVs) for intelligence gathering, logistics, and mine detection. However, traditional shipbuilding and mold-making methods are expensive and time-consuming, often requiring months to fabricate custom components.
BAAM has been successfully used to fabricate a 34-foot catamaran boat hull mold in collaboration with Alliance MG, LLC (AMG). The mold was printed in twelve sections, each approximately six feet long, over a five-day period using 5,500 pounds of carbon-fiber reinforced ABS. This rapid prototyping approach significantly reduces the time and cost needed for manufacturing large resin infusion molds, allowing naval forces to rapidly deploy new vessels with mission-specific designs.
The Military’s First 3D-Printed Submersible Vessel: A Game-Changer for Naval Operations
The U.S. Navy, in collaboration with Oak Ridge National Laboratory (ORNL) and its Disruptive Technology Lab, has pioneered a revolutionary approach to underwater military assets by developing the first-ever 3D-printed submersible hull. This groundbreaking vessel, known as the “Optionally Manned Technology Demonstrator,” serves as a prototype for future logistics deployment and sensor integration in maritime operations.
Produced at ORNL’s Manufacturing Demonstration Facility (MDF) using Big Area Additive Manufacturing (BAAM), this submersible represents the Navy’s largest 3D-printed asset to date. Unlike conventional hulls, which require 3–5 months and $600,000 to $800,000 to manufacture, the BAAM-printed version was completed in just four weeks, reducing costs by a staggering 90%. The hull itself is 30 feet long and 4.5 feet in diameter, comprising six carbon fiber composite sections that provide both strength and durability.
This initiative is part of the Navy’s broader strategy to develop on-demand, disposable, or rapidly deployable submersibles, enabling faster mission execution and enhanced adaptability in maritime warfare. By leveraging BAAM, the Navy can create customized submersible vessels tailored to specific mission parameters, significantly reducing logistical constraints. With fleet-capable prototypes expected to be operational as early as 2019, this advancement marks a paradigm shift in naval technology—one where rapid, cost-effective, and mission-specific manufacturing defines the future of maritime defense.
Aerospace and Unmanned Aerial Vehicles (UAVs)
Military forces worldwide are investing in next-generation UAVs for reconnaissance, combat support, and logistics. BAAM’s lightweight composite materials and large-scale printing capabilities make it ideal for producing aircraft fuselages, wings, and internal structures with increased strength and reduced weight. The U.S. Air Force and DARPA have explored BAAM’s potential for on-demand production of UAV components, enabling rapid field deployment without relying on traditional supply chains. Additionally, BAAM can produce stealth-optimized structures using composite materials that reduce radar signatures, enhancing the survivability of military aircraft.
Land Vehicles and Mobile Repair Solutions
Armored personnel carriers (APCs), tanks, and military trucks require frequent maintenance, repairs, and component replacements. With BAAM-enabled field manufacturing, military forces can 3D-print replacement parts on-site rather than waiting for supply chains to deliver them. This capability ensures that ground forces can maintain their vehicles in operational condition with minimal downtime. BAAM also allows for the rapid manufacturing of customized vehicle armor, offering additional protection for troops in active combat zones. On-site repair capabilities in forward operating bases (FOBs) further reduce logistical dependencies and improve battlefield readiness.
Portable Military Infrastructure
Military operations often require temporary structures that can be rapidly deployed in remote or hostile environments. BAAM is being explored for the production of lightweight, deployable shelters and reinforced structural components for mobile command centers, field hospitals, barracks, and storage units. By integrating reinforced thermoplastics with advanced insulation properties, BAAM-printed structures offer enhanced durability, weather resistance, and rapid deployment capabilities. These advancements make BAAM a crucial technology for modern military logistics and infrastructure development.
Advantages of BAAM in Defense Applications
BAAM’s greatest strength lies in its speed and efficiency. Unlike traditional manufacturing processes, which can take months to produce large components, BAAM reduces production times to mere days, ensuring faster deployment of critical assets. The technology also offers unparalleled customization and flexibility, allowing defense systems to be tailored to specific missions without requiring expensive retooling or modifications.
Cost-effectiveness is another major advantage. By using thermoplastics and composite materials instead of metal-based manufacturing, BAAM significantly lowers production costs while maintaining structural integrity. Additionally, the additive manufacturing process minimizes material waste, making BAAM a more sustainable alternative to traditional subtractive manufacturing methods.
One of BAAM’s most significant contributions to military operations is its potential for on-demand production in the field. With mobile BAAM units, military forces can manufacture essential components on-site, reducing reliance on traditional supply chains that may be vulnerable to disruptions. This capability is particularly valuable in conflict zones or remote locations where immediate access to replacement parts is critical for mission success.
Challenges and Future Developments
While BAAM represents a transformative leap in large-scale additive manufacturing, certain challenges must be addressed for broader military adoption. One of the primary concerns is material limitations. While carbon-fiber reinforced polymers and other thermoplastics offer impressive strength-to-weight ratios, ongoing research is needed to develop materials that can withstand extreme military conditions, such as high heat, intense mechanical stress, and harsh environmental exposure.
Post-processing remains another area of improvement. Although BAAM can produce large-scale components with high precision, some parts still require additional machining or finishing to meet military-grade performance standards. Enhancements in printing resolution and automated finishing techniques will be crucial in overcoming this limitation.
Scalability is also a key consideration. While BAAM has demonstrated its potential in various defense applications, integrating it into existing military logistics and production chains requires further investment and strategic planning. Future developments in BAAM will likely focus on enhancing material properties, improving automation, and expanding military applications, ensuring that armed forces worldwide can leverage large-scale additive manufacturing for next-generation warfare and defense infrastructure.
Conclusion
Big Area Additive Manufacturing (BAAM) is transforming industrial production, military logistics, and defense innovation by offering large-scale, cost-effective, and rapidly deployable manufacturing solutions. From naval vessels and UAVs to mobile infrastructure and battlefield repairs, BAAM is set to redefine how military forces design, build, and maintain their assets.
As technology continues to advance, BAAM’s integration into defense, aerospace, and maritime industries will pave the way for a more adaptable, efficient, and self-sustaining military force. With its ability to print large, complex components in a fraction of the time required by traditional methods, BAAM is not just the future of manufacturing—it is the future of military readiness and operational superiority.
