Portsmouth Naval Shipyard Welds First Ever Metal 3D-Printed Submarine Component

April 10, 2026

The USS Washington (SSN 787) arrives at Portsmouth Naval Shipyard for a scheduled maintenance availability in September 2024. In March, the shipyard announced a welding first for a 3D-printed metal submarine component. (Image: U.S. Navy photo by Neil Boorjian/released)

Engineers recently completed inspection, testing, and shipboard installation of a welded, additively manufactured (AM) copper‑nickel flange for the USS Washington (SSN‑787). The component was installed March 18 following a March 9 verification milestone, marking one of the first uses of a welded metal AM part on an in‑service U.S. submarine.

The project demonstrates a practical application of metal additive manufacturing for submarine sustainment, particularly for components traditionally constrained by long lead times or limited supplier availability. Engineering teams identified the flange as a suitable candidate for AM based on an operational need and coordinated with the maritime industrial base’s additive manufacturing center of excellence to procure the 3D‑printed part for evaluation.

Before installation, the flange underwent a full qualification process, including dimensional inspection, material verification, and weld procedure development specific to the AM copper‑nickel alloy. Welding specialists and materials engineers collaborated to validate joint performance and ensure compliance with submarine technical requirements. This included a first‑of‑its‑kind weld qualification for this AM material in a naval application.

The successful installation provides a data point for expanding AM use in submarine maintenance and modernization. It also demonstrates the feasibility of integrating welded AM components into existing systems without altering surrounding structures or interfaces.

Program officials noted that the effort supports broader initiatives to accelerate adoption of advanced manufacturing technologies across the submarine enterprise, with the goal of improving part availability, reducing production bottlenecks, and increasing readiness. The qualification of this welded AM component offers a model for future applications where conventional manufacturing timelines or tooling constraints limit fleet support.

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