Navy Completes First 3D-Printed Part Weld on Submarine

The USS Washington successfully integrated an additive-manufactured component during its recent maintenance period.

Updated on Oct. 29, 2026 in Manufacturing

Navy Completes First 3D-Printed Part Weld on Submarine

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The U.S. Navy has successfully completed the installation of a 3D-printed, welded copper nickel flange on the Virginia-class attack submarine USS Washington. This milestone occurred during a maintenance availability at the Portsmouth Naval Shipyard.

Why it matters

The use of additive manufacturing allows naval shipyards to produce critical replacement parts on demand, significantly reducing dependence on traditional supply chains and minimizing maintenance delays. This innovation helps keep naval assets operational and mission-ready.

The USS Washington (hull number 787) successfully integrated the new part following inspection and testing of the flange on March 9. The final installation was completed on March 18 during the submarine's Drydocking Selected Restricted Availability.

The players

USS Washington

This Virginia-class attack submarine serves as a critical asset in the United States naval fleet.

Portsmouth Naval Shipyard

This facility is a primary naval installation responsible for the maintenance and modernization of the United States submarine force.

The details

Personnel at Portsmouth Naval Shipyard conducted the historic weld after verifying the integrity of the 3D-printed component. The submarine, which was commissioned in 2017 and received a Presidential Unit Citation in July 2024, is now preparing for upcoming sea trials.

2017: The USS Washington was commissioned into service.
July 2024: The submarine was awarded the Presidential Unit Citation.
late 2024: The vessel entered the Portsmouth Naval Shipyard for maintenance.
March 9: The 3D-printed flange component underwent rigorous testing.
March 18: The 3D-printed flange was installed on the submarine.

Market Landscape

This development follows the U.S. Navy's additive manufacturing implementation strategy, marking a shift toward self-sustaining maintenance logistics. The technology allows the military to bypass legacy supply chain bottlenecks that previously hindered shipyard repair timelines.

For the taxpayer, this shift toward on-demand manufacturing helps reduce the costs and downtime associated with maintaining complex military hardware. Quicker repair cycles mean critical vessels spend more time at sea rather than in the shipyard.

The takeaway

The successful integration of 3D-printed parts into naval operations demonstrates how advanced manufacturing can solve long-standing supply chain issues. As the Navy scales this capability, other sectors may look to similar on-demand production models to improve their own operational efficiency.