Phillips Federal News

US Navy installs on board the first Phillips Additive Hybrid metal 3D printing solution powered by Meltio and Haas

US Navy

The Linares-based multinational relies on its US distributor, Phillips Corporation, to close the first of many historic contracts that allows the Bataan ship and others in Navy to manufacture parts and repair tools

Linares, Jaén (Spain) / Hanover, MD (US) January, 16th, 2023.– The Spanish multinational Meltio – a disruptive wire-laser metal 3D printing technology manufacturer- together with Phillips Corporation – a global manufacturing solutions leader based in the US – have worked together to install for the first time on a US Navy ship a metal 3D printing solution for the onboard manufacture of spare parts and repairs. The Phillips Additive Hybrid powered by Haas took the laser metal deposition technology of Meltio and integrated it with the world-renowned Haas CNC vertical machining centers control mill onboard USS Bataan ship.

This new project represents a further step towards demonstrating an industrially useful application in the marine sector thanks to the accessible wire-laser metal 3D printing technology developed by Meltio. Meltio collaborates with Haas on other hybrid system projects in other industries and in different countries. The Hybrid system provides subtractive and additive manufacturing. The US Navy is using a combination of these both in this particular project for USS Bataan ship.

The equipment, installed under a joint effort between the Commander, the Naval Surface Force Atlantic, and the Naval Sea Systems Command (NAVSEA) Technology Office, includes the Phillips Additive Hybrid system, which integrates a Meltio wire-laser metal deposition head on a Haas TM-1 computer numerical control mill. The Haas TM-1 platform has been proven to operate reliably in an afloat environment aboard several aircraft carriers. Integrating the Meltio deposition head with the Haas TM-1 provides both an additive and subtractive manufacturing capability within the same system – increasing efficiency and reducing waste when compared with typical machining.

3D Printer Installation

3D Printer Installation onboard USS Bataan NORFOLK, Va. (Oct. 19, 2022) Kenya Latham, assigned to East Coast Repair, coordinates the on load of a three dimensional printer aboard the Wasp-class amphibious assault ship USS Bataan (LHD 5), Oct. 19, 2022. This will be the first Naval Sea Systems Command sponsored hybrid system permanently installed on a U.S. Navy ship and will permit the capability to additive manufacture steel components locally. (Photo by Mass Communication Specialist 2nd Class Darren Newell/RELEASED).

Ángel Llavero, CEO of Meltio, says: “For us, the fact that the US Navy has incorporated Meltio’s wire-laser metal 3D printing solution and Haas hybrid equipment thanks to Phillips Corporation on board the US Navy ship to manufacture spare parts and repair them is the consequence of years of effort and a great vision that we had at Meltio. We would like to thank Phillips Corporation for their support in the development of these hybrid systems under the Haas brand, which is the consequence of confirming a technology with enormous industrial applications in the naval and marine sector, in defense, and in all those industrial sectors where it is necessary to be able to manufacture the part when and where it is needed. We are sure that this is the first step in a long way that we will have in this industrial sector of the navy with this and other applications”.

The US Navy advanced efforts to improve self-sufficiency for deployed ships and their crews and reduce supply chain lead times by leveraging additive manufacturing (AM) by permanently installing the first metal 3D printer aboard a ship. Thanks to additive manufacturing – commonly known as 3D printing – the engineers will join different materials to make parts from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing and formative manufacturing methodologies.

Whether creating a quality-of-life item or a sophisticated machine part, AM facilitates production at the point of need when time and operational availability matter.

“The introduction of additive manufacturing (AM) into naval operations supports readiness and self-sufficiency,” states Rear Adm. Brendan McLane, commander, Naval Surface Force Atlantic. “These printers have the ability to help the Navy overcome both obsolescence issues for ships and systems that have service lives measured in decades and directly contribute to enhanced operational availability of our systems and ships,” says NAVSEA Chief Engineer Rear Adm. Jason Lloyd.

The Phillips Additive Hybrid system prints 316L stainless steel, a prevalent material in US Navy ship systems. While stainless steel additive manufacturing onboard naval ships is new, it also represents an advancement in providing sailors with industrial-level manufacturing capabilities to print individual parts for systems that previously have not been readily available without procuring the entire system at a significantly greater cost.

Meltio

Phillips Additive Hybrid system, which integrates a Meltio wire-laser metal deposition head on a Haas TM-1 computer numerical control mil (Photo by Phillips Corporation)

The Meltio’s Engine 3D printing benefits are twofold – it maximizes operational availability and reduces the demand on traditional and Navy-specific supply chains. Additionally, NAVSEA engineers installed a second 3D printer to produce polymer (plastic) components onboard Bataan. This printer enables the ship’s crew to print any of the NAVSEA-developed 300+ AM Technical Data Packages that define the required design configuration and procedures to manufacture a part and ensure it performs properly.

“Phillips and Meltio are proud to be a part of Phillips Additive Hybrid installation aboard the USS Bataan. This is the first laser metal deposition (LMD) additive manufacturing technology installed aboard a naval ship,” said Brian Kristaponis, General Manager, Phillips Corporation, Hybrid Division.

“This is an optimal fit for the US Navy that is seeking to add exceptional new Additive capability to their Haas machining centers– all in one machine,” Kristaponis added. “They are leveraging this exciting new technology to improve self-sufficiency for deployed ships and their crews.”

Amphibious assault ship

Bataan, a multi-purpose amphibious assault ship, carries more than 2,500 Sailors and Marines when fully embarked, and is the fifth ship of the Navy’s Wasp-class ships. She was commissioned on September 20, 1997, and is the second U.S. Navy warship to bear the name. CVL-29 was an Independence-class small aircraft carrier that was commissioned in November 1943. After serving in both World War II and the Korean conflict, CVL-29 was decommissioned in 1954.

NAVSEA is the largest of the Navy’s six system commands, responsible for the building, buying, and maintaining of ships, submarines, and systems for the U.S. Navy. NAVSEA’s Technology Office is leading multiple areas of research and development in the evaluation of AM equipment, using data not only from deployed assets but also shoreside lab activities, to gain a critical understanding of how the equipment will perform under shipboard conditions.

About Phillips Corporation

For more than 60 years, federal government, private sector and education leaders have trusted the experts at Phillips Corporation to solve their greatest manufacturing challenges. Phillips enjoys a 30 year global relationship with Haas Automation that has produced over 30,000 installed machines. Our mission is to create legendary value for the manufacturing community by unlocking solutions to propel capabilities, profitability and productivity. Phillips represents a robust combination of equipment, applications expertise, and services that are well-suited to meet the growing range of present and future manufacturing applications requirements. Learn more about Phillips at www.phillipscorp.com

About Meltio:

Meltio takes metal additive manufacturing to the next level by developing high-performance, affordable, and easy-to-use metal 3D printing solutions using wire-laser metal 3D printing technology. The company’s mission is to delight customers, partners and employees by pioneering the development of affordable metal 3D printing systems that are reliable, safe, and powerful, continually reinforcing their status as disruptors.

Media Contact:

Sharon Riggs
443.714.4860
sriggs@phillipscorp.com
Hanover, MD

Phillips Federal News

TechSHIFT Podcast Episode 9: Heavy Hitters: The Importance of Defense Manufacturing & Future Point of Need ApplicationsDevelopment

In this episode, we sit with Jason Dickman, CTO of ClassIQ mfg has a long and significant history in the Additive Manufacturing industry. Jason shares his experiences in entrepreneurship with additive manufacturing revolving around prototyping and production for defense and many other industries.

LISTEN NOW

Phillips Federal News

TechSHIFT Podcast Episode 8: It's About the People: The Use of Advanced Technology to Scale Workforce Development

We had the opportunity to speak with Courtney Arbour, Director of the Texas Workforce Commission’s Workforce Development Division where she oversees an integrated workforce development system that provides employment and training activities for the state of Texas. Courtney gives us a glimpse into her everyday life promoting new long-lasting careers for Texans and the utilization of advanced technologies leading to the development of new technical skills across the state.

LISTEN NOW

Phillips Federal News

TechSHIFT Podcast Episode 7: Reach For The Stars: AM's Untapped Potential in Public & Private Industries In this episode

In this episode, we sit with Adam Penna of ASME to discuss public and private sector advancements in additive technologies. We’ll dive into various topics such as education, workforce development, and even space travel. Focused on the adoption of AM in all industries, and the growth of the people who work in them!

LISTEN NOW

Phillips Federal News

TechSHIFT Podcast Episode 6: Think with The End in Mind: Surface Finishing's Dirty Little Secret

In this episode, we follow the BelAir team through what is understood to be a simple and overlooked topic, “Surface Finishing”. During our discussion we breakdown the different post-processing methods leading to dramatic increases in part performance and reliability. Listen close as our team pulls back the veil of surface finishing’s best-kept secrets!

LISTEN NOW

Phillips Federal News

TechSHIFT Podcast Episode 5: Making The Change: Americas Initiative for Diverse Engineering Capabilities

In this episode, we get a real-life look into EWI’s AM Business Director Howie Marotto and his passion for people with unique skill sets, as well as the importance of capitalizing on the amazing talents that foreign nationals bring to our technical innovation. We discuss what living in America means to us and what we as a country need to do to tap into these wells of knowledge to mitigate risks around supply-chain, hypersonic threats and reduce the dilution of the American dream by expanding into the world of inclusion.

LISTEN NOW

Phillips Federal News

TechSHIFT Podcast Episode 2: Advances in Technology: How The SecureAmerica Institute is spearheading Hypersonics and more in Texas

In this episode of TechSHIFT, we welcome Rob Gorham, Executive Director of The SecureAmerica Institute for the Texas A&M Engineering Experiment Station (TEES). In this role, Rob is responsible for the development and execution of strategic manufacturing initiatives. During this podcast, Dillan Drake of Phillips Federal discusses Rob’s involvement in promoting education within lower-income families in the state of Texas and how this program is spearheading Hypersonics discussions and technical development around other advanced technologies. 

LISTEN NOW

Phillips Federal News

TechSHIFT Podcast Episode 1: Why it matters: Having a Legislative Advocate for Technologies

Join your host Dillan Drake as he speaks with Mark Burnham on the opportunities he is uncovering alongside policymakers to assist in the adoption of Additive Manufacturing (AM) with the help of his team at The Additive Manufacturing Coalition.

LISTEN NOW

Request Info On Training

Request an Additive Quote

Request a CNC Quote

Request a Service Quote

Magics Training Courses

Request a Training Quote

Service

+1 610-745-2101

Tech Support

+1 410-564-2909