Utilization of Additive Manufacturing for Rapid Repair in Military Applications

This study explores the application of Additive Manufacturing (AM) to improve the efficiency and responsiveness of spare part production in military maintenance, with a focus on Expedient Repair (ER) within the framework of Battle Damage Repair (BDR). The paper evaluates the limitations and key implementation considerations of various AM technologies in field-based repair scenarios, including classification of spare parts by criticality, material selection, design constraints, and manufacturing feasibility. A real-world case study is presented, encompassing all critical phases of the process: (1) iterative design and prototyping; and (2) reverse engineering and remanufacturing of a brake fluid reservoir for a selected ground platform-a light tactical multirole vehicle. The results validate the utility of AM in producing functional, field-ready components under operational constraints, facilitating accelerated repairs, minimizing logistical demands, and enhancing platform readiness during high-intensity military engagements.