Replacing parts or tools at sea is not as simple as ordering replacements and having them delivered. Some items can take weeks to arrive, or they may no longer be made. Wasp-class amphibious assault ship USS Essex (LHD 2) and Combat Logistics Battalion 13, 13th Marine Expeditionary Unit, are addressing supply chain challenges by using embarked 3D printers, providing our team with additive and subtractive manufacturing capabilities.
RIMPAC 2026 will feature approximately 40 experimentation initiatives, each with a respective Department of War or Department of the Navy sponsor, as part of the Fleet Experimentation Program (FLEX). Experimentation initiatives will be conducted during all phases of RIMPAC execution, including while units are pierside, underway, and aboard U.S. Navy and partner nation units. By exposing the Fleet to emerging capabilities, RIMPAC enables experimentation, providing stakeholders real-world warfighter feedback early in the acquisition process.
“We’re able to manufacture parts on site at the point of need,” said Gunnery Sgt. Samuel Margarini, 3D Printing Team non-commissioned officer in charge, assigned to Combat Logistics Battalion 13, 13th Marine Expeditionary Unit. “Whether it’s for the ship, the Marine Corps, or aviation, we’re able to solve problems without waiting on the supply chain.”
Though this capability currently does not solve all supply chain issues, it does break away from traditional manufacturing.
The processes of additive and subtractive manufacturing build or remove material from an object layer by layer from a digital model. The process begins when parts or product specifications that require a replacement are brought to the 3D printing team. The team then measures, designs a digital model, and prints a plastic prototype to verify the dimensions before producing the final product. More complex parts require technicians to use a 3D scanner to capture detailed measurements for digital recreation.
According to Margarini, technicians use plastic prototypes—quicker to make than metal ones—to test design concepts before finalizing products. This streamlines confirmation of precise measurements and fit, saving time, reducing waste, and enabling design refinement before installation.
“The traditional process requires a department to submit a job and the supply department to track, receive, and issue parts," said U.S. Navy Cmdr. Jason Pirrallo, the supply officer aboard Essex. "This capability enables the entire manufacturing process to occur on the ship, reducing administrative hurdles and the time from job submission to receipt of parts."
For the ship’s Supply Department, 3D printing provides another tool to keep Essex mission-ready.
Pirrallo states that the 3D printing program has reduced the workload on parts orders and saved money across all departments, freeing funds for other essential priorities.
“If we’re in the middle of the ocean and something breaks, instead of waiting a week or two for a replacement, we’re able to get our equipment operational right there,” Margarini said. “There are many parts on ships that are no longer manufactured. Some manufacturers no longer exist, and some parts are simply obsolete. This technology helps supplement the supply system and keeps equipment operational.”
One of Essex’s mission sets is to operate as a forward-deployed medical ship and provide humanitarian aid during a crisis. Because of this, it is essential that medical equipment is readily available.
U.S. Navy Capt. David Foster, senior medical officer aboard Essex, notes that their equipment often consists of low-volume, high-acuity parts that can be easily produced by the 3D printing team. The team has already manufactured replacement room thermostat covers and oxygen storage parts that are unavailable for purchase.
“In the future, we’re hoping to manufacture actual pieces of medical equipment that could then be sterilized and potentially used with patient care,” Foster said. As more departments learn about additive and subtractive manufacturing, the program will expand. It will become more than just replacing broken parts. This tool lets Sailors and Marines solve problems on their own instead of waiting for outside help.
“I think a lot of people still don’t fully understand the capabilities,” Margarini said. “The more people understand the technology, the more you can push and challenge the technology and help advance it.”
By producing replacement components, custom tools, or solutions for ship departments, 3D printing keeps Essex ready at sea, one layer at a time.
Thirty nations, over 30 surface ships, five submarines, 15 national land forces, more than 206 aircraft and 30,000 personnel are participating in RIMPAC in and around the Hawaiian Islands, June 24 to July 31. The world's largest international maritime exercise, RIMPAC provides a unique training opportunity while fostering and sustaining cooperative relationships among participants critical to ensuring the safety of sea lanes and security on the world's oceans. RIMPAC 2026 is the 30th exercise in the series that began in 1971.