Additive Manufacturing in Army Ground Vehicles - Air Inlet Duct Case Study

In an era where rapid technological advancements are reshaping the battlefield, the United States Army is at the forefront of modernizing its platforms to ensure unmatched performance, power, and capabilities. This modernization is not just an option but a necessity to equip the warfighter with systems that can see farther, move faster, and handle the increasing demands of modern warfare. A pivotal element in this transformation is the integration of additive manufacturing (AM) into the production of military equipment. This presentation delves into how AM is revolutionizing the design and manufacture of critical military components, using the development of an engine air inlet duct as a case study. Our presentation delves into the intricate process of designing, optimizing, and developing an additively manufactured engine air inlet duct. This component, crucial for the operation of military platforms, was subjected to harsh environmental conditions, underscoring the need for a design that could withstand extreme stresses while enhancing performance. Balancing factors such as performance, packaging, delivery, mechanical integrity, and manufacturability was paramount. The successful development of this duct stands as a testament to the power of AM in creating components that not only meet but exceed the rigorous demands of military applications.