Littleton facility growth, new metal R&D programs and certification efforts support additive manufacturing for U.S. defense use.
3D Systems reported increased activity in its aerospace and defense business, including planned facility expansion and ongoing technology development. The company cited provisions in the National Defense Authorization Act for fiscal year 2026 that restrict foreign-sourced 3D printing systems for certain Department of Defense programs, which could shift demand toward U.S.-based suppliers.
Key highlights:
- Revenue outlook: The aerospace and defense business is forecast to have grown more than 15% in 2025 and more than 20% in 2026. Revenue from production printing systems and custom metal parts is expected to exceed $35 million in 2026.
- Capacity expansion: 3D Systems plans to add up to 80,000 square feet to its Littleton, Colorado, facility to increase capacity for application development, process qualification, validation and production-scale manufacturing.
- Qualification and certification: The Littleton facility has been selected for certification under the America Makes JAQS-SQ framework to support qualified additive manufacturing production for defense applications.
- Metal printing R&D: The company is continuing an $18.5 million U.S. Air Force-sponsored program to develop next-generation laser powder-bed fusion technologies for large-format metal part production, with milestones scheduled through 2027.
- U.S. manufacturing footprint: 3D Systems said its U.S. operations span system design in San Diego, California, printer manufacturing in Rock Hill, South Carolina and metal parts production and application development in Littleton, Colorado, with plans extending to 2027.
- International operations: The company said it supports non-U.S. aerospace and defense customers through operations in Leuven, Belgium, and Riom, France, and through a joint venture in Saudi Arabia that is pursuing localized additive manufacturing for aerospace and defense applications.
The Littleton expansion supports 3D Systems’ application-focused strategy that combines hardware, materials, software and engineering support across four areas:
- Supply chain resilience: Regional manufacturing is intended to reduce lead times and supply risk for time-sensitive programs. The company cited work with Huntington Ingalls Industries on copper-nickel (CuNi30) alloy solutions for naval components to shorten production timelines.
- New application development: Through its Application Innovation Group, 3D Systems works with customers on lightweight and consolidated part designs. The expanded Littleton Center is expected to support qualification and scale-up through engineering collaboration, pilot production and technology transfer.
- Printing solutions: The company’s low-oxygen direct metal printing process is intended to support consistent output for aerospace and defense applications. In collaboration with NIAR and the America Makes Joint Metal Additive Database Definition effort, 3D Systems is working to develop material allowables on the DMP 350 platform for additional end uses, including flight applications.
- Propulsion and casting applications: QuickCast Air and additive casting workflows are used to produce complex geometries and iterate designs for aviation, space and energy applications. The company is also participating in the Penn State-led IMPACT 3.0 program focused on integrating additive manufacturing into casting and forging workflows.
For more information, visit 3dsystems.com.
