A team at Newport News Shipbuilding has successfully installed the first valve manifold assembly created by additive manufacturing technology on a new construction aircraft carrier.

NNS continues to integrate additive manufacturing, also known as 3D printing, into the shipbuilding process. The use of certified 3D-printed parts has the potential to accelerate construction and delivery of vessels to the U.S. Navy by cutting lead times and improving manufacturing quality for critical components.

The valve manifold assembly, a specialized assembly that allows distribution of a single source of fluid to multiple points on the ship, is installed in a pump room on Enterprise (CVN 80). The assembly, which is approximately 5 feet long and 1,000 pounds, reflects the shipyard’s pursuit of all opportunities to support construction using additive manufacturing. NNS collaborated with DM3D Technology to manufacture the manifold body.

This particular installation was the culmination of years of work from multiple teams. Joshua Bruns (E66), who has spent the past five years working on this project, said he was proud to see it develop from a research and development idea to a reality.

“We don’t always get to see something come to fruition, so it’s nice to see this victory,” he said. “We’re super proud. It’s been a huge team effort. I know everyone says that, but that’s definitely been the case.”

With the completion of this evolution on Enterprise (CVN 80), similar manifolds planned for Doris Miller (CVN 81) will employ additive manufacturing rather than traditional casting methods, reducing schedule risk and improving efficiency.

“What started as a proof of concept quickly turned into a tangible result that is making a meaningful difference to improve efficiencies in shipbuilding,” said Dave Bolcar, vice president of Engineering and Design. “The benefits of this innovation will extend well beyond Enterprise (CVN 80), as we incorporate our expertise in additive manufacturing into the fundamentals of shipbuilding.”

This latest advancement in the development and deployment of additive manufacturing builds on NNS’ prior certification and approval as a supplier for additive manufacturing components on Naval Sea Systems (NAVSEA) platforms. To date, the shipyard has created more than 55 additively manufactured parts installed on both new construction vessels and those currently in the fleet, with plans to install more than 200 additional parts this year.

Shea Matthews (E26) joined the project team two years ago focusing on the installation portion. He said the expansion of additive manufacturing at NNS will allow shipbuilders greater flexibility as they work to meet the company’s – and ultimately the Navy’s – goals.

“It’s another tool in our toolbox, but it’s a big tool in a toolbox that currently is not very big,” Matthews said. “In that regard, it’s huge because it offers us a substantial amount of additional flexibility.”