Lockheed Martin: Mitigating Supply Risk with 3D Printing

Lockheed Martin has embedded additive manufacturing throughout its supply chain to enhance agility, reduce lead times and mitigate production bottlenecks.

The aerospace and defence manufacturer is leveraging 3D printing technology to streamline procurement, consolidate components and create supply chain resilience across its missile and aircraft programmes.

The company's approach to additive manufacturing (AM) extends beyond simple cost reduction.

By producing parts on-demand using industrial-scale equipment, Lockheed Martin can respond more effectively to supply chain disruptions and maintain production schedules without relying solely on traditional supplier networks.

In March 2024, Lockheed expanded its Grand Prairie, US facility by 16,000 square feet to accommodate large-format multi-laser machines alongside heat treatment and inspection equipment.

"We continue to invest in AM technology to provide value for our customers in a way that empowers our engineers to innovate and rapidly integrate new product designs and capabilities to the production floor," says Tom Carrubba, Vice President of Production Operations at Lockheed Martin Missiles and Fire Control.

"This allows us to create affordable and modular designs that can simplify both high and low-volume production processes."

Reducing supply chain dependencies

AM builds objects layer by layer from digital files. A computer-aided design (CAD) file is sliced into thin horizontal layers by software, and machines deposit material where needed for each layer. Each layer fuses to the one below using heat, light or chemicals.

This process reduces raw material procurement requirements because material is added rather than cut away. For supply chain managers, this presents an opportunity to reduce inventory costs and material waste.

Traditional manufacturing methods require complex parts to move through multiple suppliers and processes. AM can consolidate assemblies that would typically require tens of different parts from various suppliers to be bolted or welded together. This consolidation reduces the number of supplier relationships to manage and potential points of failure.

By minimising dependencies on external suppliers for certain components, Lockheed Martin gains greater control over its production timeline. This strategic advantage becomes particularly valuable during periods of supply chain volatility or when geopolitical factors affect traditional sourcing routes.

Supply chain resilience

Lockheed's Advanced Manufacturing Technology Centre opened in Grand Prairie, US in January 2024 to enable rapid development and deployment of manufacturing technology solutions. The facility supports the company's 1LMX programme, which aims to transform end-to-end business processes and systems.

Tom adds: "I am proud of the team for putting our vision into action. We have created a collaborative workspace to rapidly enhance our current production lines and to utilise our newer advanced manufacturing solutions early in our development programs. The excitement and energy our team has in making our Future Factory a reality is allowing us to meet the needs of our customer's evolving challenges."

The F-35 Training & Logistics team delivered the first two 3D printed cockpits for the F-35 Full Mission Simulator on 15 August 2022. According to Lockheed Martin, this could reduce the total lead time to obtain conventional parts by 75%. The total part count of conventional metal parts is also reduced by 70%.

These reductions have significant supply chain implications. Fewer parts mean fewer supplier relationships to manage, reduced inventory complexity and shorter procurement cycles.

Printed parts as supply chain insurance

On 12 May 2020, Lockheed used 3D printing to help create a Precision Strike Missile. Three parts were printed for a US Army-tested missile which performed in a test that saw the missile fired approximately 85 kilometres to the target area.

Printed parts are durable, provide flexibility and act as an extension of the company's supply chain, allowing production teams to meet schedule requirements in the event of an issue. This capability proves particularly valuable when traditional suppliers face disruptions or when rapid design changes are needed.

When Lockheed's team began working on 3D printed cockpits, the complex part had to be redesigned with a focus on manufacturability. Digital twin technology was used to visualise the production floor and understand where components could be inserted across the line.

The ability to print replacement parts on-demand also reduces the need to maintain extensive inventories of spare components. This just-in-time manufacturing approach lowers warehousing costs whilst ensuring critical parts remain available when production demands require them.