The US Marine Corps is revolutionising military logistics by implementing 3D printing behind enemy lines, allowing forces to produce critical components directly in contested environments. This strategic capability enables Marines to maintain combat effectiveness when traditional supply chains are compromised or inaccessible, addressing a key challenge identified in the 2018 National Defence Strategy.
As great power competition reshapes military priorities, the Marine Corps has responded with significant advancements in additive manufacturing capabilities. These innovations are particularly crucial for Expeditionary Advanced Base Operations (EABO), where distributed forces must operate with substantial self-reliance in contested areas against sophisticated adversaries.
Marine Corps Advances 3D Printing Behind Enemy Lines
The Program Manager for Combat Support Systems (PM CSS) at Marine Corps Systems Command is integrating additive manufacturing into frontline operations through the Tactical Fabrication (TACFAB) and Expeditionary Fabrication (XFAB) systems. These platforms enable forward-deployed units to produce essential components on demand, from unmanned aerial system parts to vehicle repairs.
“Additive manufacturing capabilities are revolutionising the Marine Corps across the range of military operations by flattening the supply chain and enhancing the Marine Air Ground Task Force ability to achieve truly distributed operations.”
– Terry Ritchie, product manager for Maintenance and Support Systems
The XFAB system provides deployable workshops equipped for 3D printing and scanning, giving Marines the ability to fabricate repair parts and develop customised solutions directly in the field. Metal printing capabilities are planned for fiscal year 2026, further expanding the range of components that can be produced in forward operating environments.
These systems are already proving their value in real-world scenarios. During RIMPAC 2024, Marines and engineers demonstrated onboard 3D printing capabilities on the USS Somerset, successfully manufacturing a critical component for the ship’s reverse osmosis pump after the original part failed, maintaining operational readiness at sea.
Enhancing Supply Chain Resilience
The Marine Corps is also developing a globally accessible digital repository known as the Digital Manufacturing Data Vault. This system ensures technical data packages for part fabrication are available across all logistics levels and can be shared with joint and allied partners, addressing intellectual property challenges while mitigating supply chain disruptions.
To strengthen logistics networks further, the Corps is actively collaborating with allies to leverage host nation manufacturing capabilities. Work with Australian partners in Darwin, Northern Territory, exemplifies these efforts to expand the network of production nodes throughout the Indo-Pacific region.
“If you look systemically, what additive manufacturing is bringing to the issue of logistics for a contested environment and the tyranny of distance in the Pacific—or any contested space—is a supplemental source of supply. It’s not about replacing the existing supply system or original equipment manufacturers; it’s about providing another sourcing option to fill gaps.”
– Major Matthew Audette, Advanced Manufacturing Systems Team lead
Learning from Ukraine’s Battlefield Innovations
Ukraine’s implementation of 3D printing on the battlefield offers valuable insights into how this technology can sustain combat readiness in contested environments. Ukrainian forces have demonstrated remarkable agility in using additive manufacturing to overcome logistical challenges, with one Ukrainian warfighter noting that “every single first-person-view drone strike relies on at least one 3D-printed component.”
American companies like KVG have deployed industrial 3D printers to Ukraine, supporting the design, testing, and refinement of components now used on the frontlines. These real-world applications showcase how additive manufacturing enables rapid adaptation and innovation in active combat zones.
The Ukrainian experience highlights the advantages of a more decentralised acquisition approach that allows direct engagement with industry to field cutting-edge technology at near-market speed—a model that may inform future Marine Corps logistics strategies.
Overcoming Challenges for Future Combat Readiness
Despite significant progress, several challenges must be addressed to fully realise the potential of 3D printing behind enemy lines. Access to technical data packages from original equipment manufacturers remains limited, with proprietary designs often unavailable for military reproduction. The Digital Manufacturing Data Vault must evolve to better manage intellectual property, potentially through licensing arrangements that adequately compensate manufacturers.
Training standardisation is another priority, with logistics experts working to develop certification programs that ensure Marines are proficient in additive manufacturing techniques. This aligns with Talent Management 2030 goals of developing and retaining skilled personnel adaptable to evolving operational challenges.
“When Marines are properly trained in additive manufacturing, they can deliver solutions that greatly enhance readiness while saving taxpayer dollars,” noted Major Audette.
As the United States prepares for potential conflicts across diverse theatres, the Marine Corps continues to position 3D printing as a critical enabler of logistics resilience. By enabling production capabilities closer to the point of need, these technologies ensure that the Joint Force and international partners can sustain operations wherever required, even when traditional supply chains are compromised.
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