PEARL HARBOR, Hawaii, Nov. 14, 2025 —
In a landmark example of innovation and teamwork, the U.S. Submarine Force, Naval Sea Systems Command (NAVSEA), and U.S. Coast Guard successfully partnered to resolve a critical equipment casualty aboard USCGC KIMBALL (WMSL 756). On August 21, KIMBALL crew members reported a broken bracket, a part of the circuit breaker pre-configured “assembly” (i.e., a unit with multiple parts that are only sold together). This assembly was in the bow thruster system, which is indispensable for maneuvering in tight spaces (e.g., near piers and other vessels). The KIMBALL would need this equipment repaired to set sail on time to carry out Coast Guard missions.
KIMBALL’s crew realized that purchasing a new pre-configured circuit breaker assembly would be time-consuming and expensive, taking about 24 weeks and costing more than $16,000.00. Therefore, the crew chose to only repair the bracket inside the assembly, using an additive manufacturing (AM) solution, which is a process for building a three-dimensional (3D) object one layer at a time to form the desired shape, using 3D printing. The ability to fabricate individual parts rather than purchasing an entire replacement assembly is a major advantage of AM.
After determining the way forward, KIMBALL’s crew reached out to the Surface Fleet Logistics Center’s Industrial Operations Division (SFLC-IOD), which engaged the closest AM team in Alameda, Calif., and requested a prototype of the broken bracket. The team received the failed part and quickly designed and printed a test bracket; however, their shop did not have the required material or printer for final part production.
Thus, SFLC-IOD engaged Base Portsmouth, Va., which had the necessary material and printer, to create the test part. Base Portsmouth succeeded, but there was still another problem to resolve--it would take too long to ship the bracket from Va. to Hawaii, interfering with KIMBALL’s sail date schedule.
SFLC-IOD’s AM team needed to find someone with the essential end-stage production equipment--closer to Pearl Harbor and available for use. So, they reached out to NAVSEA, which identified the Navy’s fast-attack submarine USS CHARLOTTE (SSN 766) as a unit that could assist.
The SFLC-IOD AM team leader sent the 3D printing files to CHARLOTTE’s crew members, and they fabricated the final replacement part using the submarine’s onboard equipment. On August 30, Senior Chief Petty Officer Patrick Mullins, a U.S. Navy Fire Control Technician, hand-delivered the part to LT Kyle Carosotto, USCGC KIMBALL. Then, the Coast Guard crew successfully tested and installed the part—restoring the bow thruster to full operation in time for the cutter’s scheduled sail date.
In addition to the immediate benefits of this critical repair, this effort provided long-term benefits, like reinforcing cross-Service partnerships and demonstrating the value of early engagement with skilled operators and maintaining a strong, collaborative professional network. These relationships help our Service to be better prepared for the future.
This effort also highlights AM, an innovative solution that is helping to reshape readiness across the Navy and Coast Guard by delivering faster solutions, saving money, and enabling operational self-sufficiency at sea.
James S. Pluta, Afloat/Expeditionary Advanced Manufacturing and Repair Program Manager, U.S. Navy Direct Reporting Program to the Maritime Industrial Base, emphasized the positive outcomes of this effort, saying: “This case further exemplifies the importance of having an additive manufacturing capability deployed widely and sufficiently training our Service members to use it. It highlights the lead-time reduction as well as cost savings commonly seen when additively manufacturing components within the lowest replaceable unit of a damaged system. Additionally, it showcases our close collaboration with our Coast Guard partners who knew whom to contact for support with this short-fused request. This is a positive sign for the future of this enabling capability in the maritime environment.”
For additional information on the Coast Guard’s 3D printing, please contact LCDR Andrew Armstrong, National Industrial Enterprise Branch Chief and Surface Fleet Additive Manufacturing Lead, SFLC-Industrial Operations Division, at the following link: Andrew.Armstrong@uscg.mil.