Grainger College and DOD Launch $9 Million Project for Military Vehicle Parts

The Grainger College of Engineering has entered into a partnership with the U.S. Department of Defense (DOD) to explore innovative applications of 3D printing in the engineering of large metal parts for military vehicles. Announced in May 2025, this project is valued at $9 million, with the DOD contributing $8.15 million to the initiative.

Led by Bill King, the Ralph A. Andersen endowed chair and professor in Engineering and Medicine, the project aims to develop laboratory capabilities for large metal additive manufacturing. Although King declined to provide further comments, he indicated that the project is well underway, with plans for additional announcements later this year.

Investing in Advanced Manufacturing

The contract details, obtained by The Daily Illini through a Freedom of Information Act request, reveal significant expenses associated with the project. Notably, the purchase of two metal 3D printers is projected to cost around $1.2 million and $2.5 million. The University of Illinois will contribute $905,000 towards the construction of a facility located in the University’s Research Park, designed to house these advanced machines.

While additive manufacturing has gained traction in both defense and civilian sectors, its effectiveness in producing larger metal components—specifically those measuring three feet or more—remains largely untested. Federico Sciammarella, executive director of the Illinois Manufacturing Institute, which will oversee the project, noted that the center has been in the planning stages for the past two years. He emphasized that the research will extend beyond military applications to include aerospace and automotive sectors.

Outgoing Senator Dick Durbin, D-Ill., commended the initiative, stating that it will reduce U.S. reliance on foreign manufacturing for metals. He emphasized that this collaboration with the Rock Island Arsenal, a historic defense manufacturing facility, will enhance the resilience of military vehicles and create job opportunities for residents of Illinois.

Future of Additive Manufacturing in Defense

The Pentagon has been ramping up investments in additive manufacturing, aiming to incorporate this technology into military logistics. The latest military budget includes a request for $3.3 billion dedicated to additive manufacturing projects, marking an 83% increase from the previous fiscal year.

According to John Borrego, an expert in additive manufacturing and executive at Machina Labs, this shift towards 3D printing is crucial for establishing a more agile supply chain. He explained that deploying additive factories at forward bases could facilitate the repair or production of essential components for military operations. This technology allows for parts to be printed remotely, reducing the need for onsite machinists.

Despite the potential benefits, Borrego raised concerns regarding the structural integrity of 3D printed components. He noted that the melting of metal can lead to microfissures and cracks, which may pose risks, particularly for critical military applications where weight and strength are paramount.

Critics of the partnership, such as the student organization Students for Justice in Palestine UIUC, have voiced their opposition, characterizing the collaboration as a means of fueling the “war machine.” The group has organized protests and expressed their concerns through social media, urging faculty to reject participation in defense-related projects.

In response, Patrick Wade, director of executive communications and issues management at the University, clarified that the DOD projects typically focus on basic research with applications beyond national security. He emphasized that the current project does not support weapons development.

The partnership between Grainger College and the DOD represents a significant advance in additive manufacturing research, with potential implications for both military and civilian sectors. As the project develops, the involved parties are committed to addressing the challenges and opportunities presented by this emerging technology.