BUILDING IN 3D
“You can make a bridge utilizing this tech- nology. Over 30 of these [box beams] were printed over a span of three days,” Kreiger said. Seven box beams were able to create a crossing over a 40-foot gap designed to carry a fully-loaded heavy expanded mobility tactical truck.
Tere are 3D printing abilities available also for small structures, such as Jersey barriers, small bunkers and culverts. Kreiger added that during a test event they were able to print one Jersey barrier in less than an hour and up to six Jersey barriers in approximately three hours.
The Additive Construction program currently has more than 12 printers in different stages of development—the ACES Lite is the most used and has gone through several version iterations based on feedback and field use. Kreiger emphasized the many options that the program offers such as the type of materials that can be
“Our real goal as a program is to produce expeditionary structures on demand in the field by Soldiers using locally available materials.”
used to mix the concrete and the type of concrete mixer used to print. “Te idea is that you work with whatever military equipment is already available. So, you’re not having to have some customized mixer and some customized material,” Kreiger said. “You’re trying to use those locally available materials and your local equip- ment assets in order to get the job done.”
Additionally, users are not restricted by their geographic location and can choose
where the 3D printing is performed, whether that is on-site or in a warehouse, and then deliver the product (whole or in sections, depending on the size). Users also have opportunities to design the size and shape of the product. “You can start getting into more exciting applications like what can you do with the exterior of an object now that you have increased complexity in design with little added cost,” Kreiger said. “What do you want your buildings to look like? Now you can have improved and modern infrastructure because the printer will not care about the complexity of the design and print out exactly what the design file dictates. Tis extends even to internal geometries of objects as well, such as print struc- tures with solid or zigzag infill patterns [concrete is laid down in chevron lines], and we do all of it depending on what the application is.”
CONCRETE CUSTOMIZATION
Close up of the ACES Lite system printing concrete gap crossing sections. The ACES 3D print system allows the user to customize the shape, thickness and patterns of what they need. (Photo by Jared Eastman, USACE-ERDC)
WORK SMARTER, NOT HARDER A major benefit of additive construction is that it reduces both time and the number of military personnel compared to conven- tional construction. It is a well-known fact that conventional construction requires a substantial amount of physical labor. It also requires specialized skills, and not all military personnel may have the necessary training. “Really where the limitations came in is when people are producing structures in expeditionary environments,
12 Army AL&T Magazine Spring 2025
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