Charles R. Goulding and Preeti Sulibhavi explore how President Trump’s Golden Dome missile defense plan is accelerating the fusion of 3D printing and aerospace innovation.
On May 21, 2025, President Trump unveiled the “Golden Dome,” a proposed space-based missile defense system estimated to cost US$175 billion. Drawing inspiration from President Reagan’s Strategic Defense Initiative, Israel’s Iron Dome, and the establishment of the U.S. Space Force, the Golden Dome aims to integrate cutting-edge technologies to bolster national security. A cornerstone of this initiative is the incorporation of advanced 3D printing techniques, essential for creating lightweight, durable components suitable for the harsh conditions of space.
3D Printing: A Game Changer for Aerospace and Defense
Additive manufacturing has revolutionized the aerospace and defense sectors. Its ability to produce complex geometries with reduced weight and material waste makes it ideal for space applications. For instance, SpaceX’s SuperDraco engine, utilized in the Dragon V2 spacecraft, features a combustion chamber entirely 3D printed from Inconel, a high-strength nickel-chromium alloy. This approach not only reduces manufacturing time but also enhances performance by incorporating intricate cooling channels directly into the design.
Similarly, Relativity Space has embraced 3D printing to construct up to 85% of its Terran 1 rocket. Their proprietary Stargate printer, touted as the world’s largest metal 3D printer, enables rapid production of large rocket components, significantly cutting down on labor and assembly time.
Integrating 3D Printing into the Golden Dome
The Golden Dome’s ambitious scope necessitates the use of 3D printing to meet its design and operational requirements. Key areas where additive manufacturing will play a pivotal role include:
- Satellite Components: Producing lightweight structural elements and intricate parts for satellites to enhance maneuverability and payload capacity.
- Missile Interceptors: Fabricating complex geometries for interceptor components, optimizing aerodynamics and reducing weight.
- Space-Based Sensors: Creating housings and mounts for sensors that require precise alignment and durability in space environments.
These applications underscore the necessity of 3D printing in achieving the Golden Dome’s objectives of rapid deployment, cost-effectiveness, and adaptability.
New Players Disrupting Traditional Defense Manufacturing
The Golden Dome initiative has attracted a mix of established defense contractors and innovative tech companies. Notably, Palmer Luckey’s Anduril Industries is developing the Fury, an autonomous fighter drone designed to operate alongside manned aircraft. The Fury’s modular design allows for decentralized manufacturing across various U.S. workshops, emphasizing affordability and scalability.
Anduril’s approach challenges traditional defense manufacturing paradigms by leveraging commercial components and streamlined production processes. This shift towards agile development and rapid prototyping aligns with the Golden Dome’s emphasis on integrating advanced technologies efficiently.
Advancements in Materials and In-Space Manufacturing
Recent breakthroughs in materials science have further expanded the capabilities of 3D Printing for aerospace applications. NASA’s development of GRX-810, a 3D-printable superalloy, exemplifies this progress. GRX-810 offers exceptional strength and heat resistance, making it ideal for components exposed to extreme conditions in space.
In addition to Earth-based manufacturing, in-space 3D printing is gaining traction. Redwire Space (formerly Made In Space) has pioneered the use of 3D printers aboard the International Space Station, enabling astronauts to produce tools and parts on-demand. This capability reduces reliance on Earth-based resupply missions and enhances the sustainability of long-duration space operations.
The Research & Development Tax Credit
The now permanent Research and Development (R&D) Tax Credit is available for companies developing new or improved products, processes and/or software.
3D printing can help boost a company’s R&D Tax Credits. Wages for technical employees creating, testing and revising 3D printed prototypes are typically eligible expenses toward the R&D Tax Credit. Similarly, when used as a method of improving a process, time spent integrating 3D printing hardware and software can also be an eligible R&D expense. Lastly, when used for modeling and preproduction, the costs of filaments consumed during the development process may also be recovered.
Whether it is used for creating and testing prototypes or for final production, 3D printing is a great indicator that R&D Credit-eligible activities are taking place. Companies implementing this technology at any point should consider taking advantage of R&D Tax Credits.
Conclusion
The Golden Dome represents a significant leap forward in missile defense, integrating state-of-the-art technologies to address emerging threats. Central to its success is the adoption of 3D printing, which offers unparalleled advantages in design flexibility, weight reduction, and rapid production. As the defense industry continues to evolve, the fusion of additive manufacturing with aerospace innovation will be instrumental in shaping the future of national security.
