First welded 3D-printed component installed on US Navy’s Virginia-class sub

March 24, 2026, by Fatima Bahtić

Portsmouth Naval Shipyard has inspected, tested, and installed the first welded additively manufactured (AM) flange aboard the US Navy’s attack submarine USS Washington (SSN 787), marking a milestone in submarine maintenance and advanced manufacturing.

The event marks both the first time an additive-manufactured copper-nickel flange has been welded at a public shipyard and one of its first applications for in-service submarine use.

The initiative for immediate AM implementation across the submarine force originated from a directive issued by the direct-reports portfolio manager for submarines, Vice Adm. Robert Gaucher, who was serving as commander of Submarine Forces at the time.

The yard’s engineering and planning material support division identified a potential application for AM materials to meet an operational need for Washington. The shipyard coordinated with the maritime industrial base’s center of excellence to acquire this 3D-printed component and deliver it to the shipyard’s receipt inspection division.

In a first-of-its-kind process, the flange underwent thorough testing and inspections to certify that it met all requirements. Concurrently, a dedicated team of engineering and trade experts successfully completed a full weld qualification on the new material.

“The unique nature of this momentous achievement is a testament to the strong teaming and innovation that PNSY is known for,” said Capt. Jesse Nice, shipyard commander.

“For the first time, we forged a submarine component that met the fleet’s most rigorous technical specifications. This was the result of one team, with a single mission —getting the job done correctly and safely.”

“Portsmouth Naval Shipyard is leading the organic industrial base in the production and installation of additively manufactured submarine components,” said Capt. Jason Deichler, commodore Submarine Squadron TWO.

“This is truly a war fighting enabler and a key component to enhanced undersea readiness.”

USS Washington (SSN 787) was commissioned on October 7, 2017. Designed for a broad range of missions, the submarine is capable of anti-submarine warfare, anti-surface ship operations, intelligence gathering, surveillance, reconnaissance, and strike missions in both open-ocean and littoral environments.