In the defense industry, where precision, performance, and reliability are paramount, the manufacturing process itself plays a crucial role in determining overall cost and efficiency. Traditional methods often involve long lead times, high material waste, and costly tooling. Metal additive manufacturing (AM) offers a transformative solution, delivering cost savings and operational efficiencies without compromising quality — making it an ideal fit for defense applications.

Maximizing Raw Material Utilization

One of the most immediate cost-saving advantages of metal AM is its ability to drastically reduce material waste. Traditional manufacturing methods like machining or forging are inherently subtractive processes — parts are carved or milled from solid blocks of metal, generating a significant amount of scrap material. . This is especially beneficial in defense applications where high-performance materials like titanium, Inconel®, and stainless steel are essential, but costly and challenging to source in remote environments.

In contrast, AM is an additive process that builds parts layer by layer, using only the material needed to create the component. This not only reduces waste but also makes it more feasible to use expensive, high-strength alloys, as nearly all the raw material is converted into the final part. Less waste means lower material costs and a more sustainable manufacturing process — a crucial advantage when producing specialized, mission-critical components.

When producing parts in austere environments, maximizing raw material utilization is critical. AM’s ability to minimize scrap ensures that every bit of material is used efficiently, allowing defense forces to create mission-ready components while conserving valuable resources.

Eliminating Tooling Costs

Traditional manufacturing often requires custom tooling, molds, and fixtures for each new part or design variation. These tools can be expensive and time-consuming to produce, especially for low-volume production runs — common in defense manufacturing, where many components are produced in small batches or even as one-offs.

Metal AM eliminates the need for tooling altogether. Parts are produced directly from digital designs, meaning manufacturers can move from concept to production without the added time and cost associated with tooling. This flexibility also allows for rapid design iterations and prototyping, accelerating the development of new technologies and reducing overall project timelines.

Faster Lead Times

In defense manufacturing, time can be as critical as cost. Traditional processes often involve long lead times due to complex supply chains, reliance on specialized suppliers, and time-consuming machining steps. AM simplifies the process, enabling on-demand production of parts directly at the point of need.

This speed is especially valuable for maintaining aging equipment, where original parts may no longer be in production. Rather than waiting months for a replacement, defense forces can produce parts locally or through trusted suppliers, ensuring mission readiness while reducing downtime. The ability to quickly produce prototypes and test new designs also shortens development cycles, helping defense contractors stay ahead of evolving threats.

Cost-Effective Low-Volume Production

Many defense applications involve producing highly specialized components in limited quantities. Traditional manufacturing struggles with the economics of low-volume production because setup costs, tooling, and labor expenses are spread across fewer units — driving up the cost per part.

Metal AM thrives in this environment. Since there’s no need for tooling and minimal setup time, producing just a handful of components is far more cost-effective. This makes AM an ideal choice for customized, mission-specific parts, spare parts, and experimental prototypes, where flexibility and precision matter more than mass production.

Greater Efficiency with Nikon SLM Solutions

At Nikon SLM Solutions, we’re driving the evolution of defense manufacturing with cutting-edge metal additive manufacturing (AM) systems that maximize efficiency and material utilization. Our NXG series and SLM®500 deliver industry-leading build rates and exceptional material flexibility, while advanced powder handling systems enable fast material changes — keeping production agile and uninterrupted.

We go beyond providing machines; we offer a full ecosystem of materials and expert support. Our application engineers collaborate closely with customers to refine designs, select the right materials, and optimize every step of the production process for peak performance and efficiency.

By leveraging Nikon SLM Solutions’ technology and expertise, defense manufacturers gain the ability to produce mission-critical components faster, reduce material waste, and eliminate costly tooling. The result is a more responsive, cost-effective supply chain that enhances mission readiness and strengthens national security.

Our Mission, to Empower Yours

To learn more about how Nikon SLM Solutions can help you optimize your manufacturing processes, please contact our team.