Northrop's 3D Printed Tanks: A New Certification Challenge

The Future of Space Hardware: Single-Piece 3D Printed Tanks \\[n] In the world of additive manufacturing, the parts that are easiest to print often pose the greatest challenges when it comes to certification. This paradox was highlighted by Andrew Thompson, Manager of Northrop Grumman’s Additive Manufacturing Center of Excellence, during the recent AMA: Aerospace, Space & Defense 2025 conference. While the company is already printing hundreds of thousands of tooling parts annually, the focus is now shifting to more critical components, such as propellant tanks, which can significantly reduce costs and lead times. \\[n] ## From Brackets to Tanks: Scaling Up Additive Manufacturing \\[n] Thompson envisions scaling up the technology from smaller brackets, which save programs around $5,000, to larger tanks that could save upwards of $500,000. The key to this transition lies in the ability to print single-piece tanks, eliminating the need for complex welding and forging processes. Using directed energy deposition (DED) in titanium Ti-64, Northrop Grumman has successfully created a single-piece propellant tank. This innovative approach not only simplifies the manufacturing process but also reduces lead time by about 50% and cost by approximately 30%. \\[n] ## The Inspection Dilemma \\[n] However, the ease of printing these single-piece tanks comes with a significant hurdle: non-destructive evaluation (NDE). Traditional inspection methods are not well-suited for these monolithic structures, making it challenging to ensure their reliability in the harsh conditions of space. Thompson emphasized that the next generation of NDE techniques will be crucial for certifying these tanks for spacecraft flight. \\[n] ## What This Means for ASEAN Factories \\[n] For factories in Thailand, Vietnam, Indonesia, and Malaysia, the advancements in 3D printing and additive manufacturing offer both opportunities and challenges. As these technologies become more accessible, local manufacturers can leverage them to produce high-value, complex components at a lower cost. However, the certification and inspection processes must keep pace with the rapid developments in 3D printing. Collaboration with international partners and investment in advanced NDE techniques will be essential for ASEAN factories to stay competitive in the global market. \\[n] ## Concrete Takeaway for Factory Buyers \\[n] For factory buyers in the ASEAN region, the key takeaway is to embrace the potential of 3D printing while being mindful of the certification and inspection challenges. Investing in training and equipment for advanced NDE techniques, and partnering with experienced players like Northrop Grumman, can help navigate these hurdles and unlock the full benefits of additive manufacturing. By doing so, ASEAN factories can position themselves at the forefront of the next industrial revolution.