The United States Navy is facing a significant challenge. By 2028, it aims to deliver one Columbia-class ballistic missile submarine and two Virginia-class attack submarines annually, all while maintaining its existing fleet. To tackle this ambitious objective, the newly established Maritime Industrial Base (MIB) was formed in 2024 to revitalize shipbuilding and repair within the Navy. To meet production goals, innovative solutions are needed to reduce bottlenecks, enhance throughput, and reinforce supply chains. A key part of this strategy is the MIB Program’s investment in General Dynamics Electric Boat and Lincoln Electric, particularly in integrating additive manufacturing into the construction of nuclear submarines.
With funding from the MIB Program, General Dynamics Electric Boat plans to source essential components from Lincoln Electric’s new large-scale metal additive manufacturing facility. Ken Jeanos, vice president of supply chain, materials, and logistics for General Dynamics Electric Boat, emphasized the ongoing challenge of material availability, stating, “Material availability continues to drive construction delays across the submarine enterprise.” He believes that 3D-printed parts could speed up construction and delivery of submarines to the U.S. Navy by minimizing lead times for critical components.
Lincoln Electric is prepared to produce these components using four advanced SculptPrint machines at its Additive Solutions facility in Cleveland, Ohio. These systems utilize wire-arc additive manufacturing (WAAM) or gas metal arc directed energy deposition (GMA-DED), which are well-suited for creating large, mission-critical metal parts required in submarine construction. This technology excels in delivering high deposition rates and precise control over the build process, resulting in dense, fully fused metal components with superior mechanical properties.
A standout feature of Lincoln Electric’s approach is its strong vertical integration; the company manufactures everything in-house, from wire feedstock to process software. This control helps reduce supply chain risks and maintain quality throughout production.
The applications of WAAM in submarine production are varied. Lincoln Electric identifies numerous potential uses for the technology, including structural and hull components, propulsion components, and complex fittings—especially components that are challenging and expensive to cast or forge. The submarine industry often prioritizes low-volume, high-value components, making lead-time reduction and design flexibility critical.
However, merely printing the parts is just one hurdle; qualifying them for use presents another challenge. Integrating additive components with existing design codes and certification processes established by organizations like NAVSEA remains difficult. Lincoln Electric actively collaborates with government bodies and industry partners to establish material datasets and qualification standards that facilitate the integration of WAAM parts into naval programs. Currently, Lincoln Electric has secured approvals from NAVSEA and other commercial entities, paving the way for broader implementation of WAAM technology in defense applications.
This initiative builds on years of partnership between Lincoln Electric and the U.S. Navy. The investment from the MIB Program marks the largest government-backed additive manufacturing capital investment for Lincoln Electric thus far. Jeanos noted, “This Maritime Industrial Base investment is a pivotal step to further unlock AM capabilities, enabling the defense industry to address complex supply chain challenges with innovative, efficient solutions.”
As the U.S. Navy strives to achieve its ambitious production targets, additive manufacturing is poised to play a vital role in fortifying the country’s industrial base. Through the promotion of technologies like WAAM, initiatives such as MIB are facilitating the modernization of shipbuilding processes, enhancing supply chain resilience, and ensuring that the U.S. submarine fleet meets future challenges effectively.