UltiMaker Factor 4: Defence 3D Printing for the Australian Navy

Deployable fabrication is the DAMR container's core mission. It supports logistics, defect repair, and underway repair across the integrated force. Three printers sit inside the container, including the UltiMaker Factor 4 alongside a Prusa Core One and a Markforged X7. Later in 2025, a Fusion F3 joins the fleet, bringing the DAMR to four printers in total.

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The DAMR Project, Australia's First Deployable Navy 3D Printing

Navy Logistics and Infrastructure Branch (NLIB) sponsors the DAMR under expeditionary logistics. Day-to-day management sits under the Navy Minor Capital Program. Global Defence Solutions in Nowra built and delivered the shipping container, and its first full operation took place in the field during Talisman Sabre 2025. Four Fleet Support Unit sailors operate the system, each bringing a different trade background to the design and manufacture cycle.

Each printer inside the DAMR has a defined role. Prusa Core One handles fast, single-polymer prototyping. UltiMaker Factor 4 produces precise final products using dual filaments. Markforged X7 prints with a proprietary carbon-reinforced polymer rated nearly as strong as metal. A 3D scanner inside the container captures dimensions for computer-aided drawing and modelling work.

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Why the UltiMaker Factor 4 Fits Defence 3D Printing Roles

UltiMaker designed the Factor 4 for high-mix, low-volume engineering production. Dual filament output lets operators print a part and its support material in one job, then dissolve or break the support away. Defence 3D printing teams use the same workflow to produce parts with overhangs, internal cavities, and complex geometries where single-extruder machines cannot match.

Engineering polymers compatible with the Factor 4 include Tough PLA, PETG, PA, and PET CF carbon-fibre composite. A closed build chamber with active temperature control delivers repeatable parts batch after batch. User-friendly controls and robust build hold up across the harsh conditions inside a Navy container at sea.

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Inside Exercise Talisman Sabre 2025, Factor 4 in the Field

DAMR operators produced several projects across the exercise. Communication switches, a drone controller, fan brackets, and ground pegs for tents all came off the printers. One standout job was a communications box 'exoskeleton' designed to protect cables from damage for United States forces operating in the area. HMAS Choules requested another part during the exercise. The DAMR team printed it and flew it to the ship via the Maritime Support Drone (Air variant), an automated drone with remote pilot monitoring.

Marine Technician Able Seaman Lachlan Hannan operated the DAMR during the exercise. An engineering mindset shaped his approach to the additive manufacturing work.

"I already have the background knowledge on how things work, how they are supposed to be made and what things should be considered when designing," Able Seaman Hannan said.

Hannan's communications box exoskeleton project protected cables for the United States forces working alongside the Australian team.

"It provides a chance to show multinational interoperability, that they can rely on us to provide them with last-second engineering controls," Able Seaman Hannan said. "There's a lot of small fixes that we can assist with in an operational environment; there's plenty of things that break, and people just work around, but we can provide assistance to fix those issues that eases the stress of people on the deployments."

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What the Navy Learned About Deployable 3D Printing

Brendan Funnell is Deputy Director of Innovation and Continuous Improvement at the Navy Centre for Innovation. Funnell deployed on Talisman Sabre as a key contributor to the project, and he framed the exercise as a learning round for the deployable capability.

"The container is helping us learn how reliable the printers are and identify any faults the glossy datasheet doesn't tell you," Mr Funnell said. "None of these printers are designed to work at sea, but some of them handle it well."

Longer-term, the goal is broader. Defence 3D printing inside the DAMR is built to support the integrated force, with the Fusion F3 expanding capacity to four printers and metal additive manufacturing on the technology roadmap. United States Navy investment in deployable metal 3D printing is the reference path, and the Royal Australian Navy is studying a parallel route.

"The end goal is that the capability supports the integrated force, and if people on a ship have a problem, they can just go below and print something," Mr Funnell said.

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What This Means for Australian Defence Buyers

Australian defence engineering teams, sovereign manufacturers, and tertiary research labs gain a proven reference for defence 3D printing from this deployment. Royal Australian Navy selection of the UltiMaker Factor 4 for DAMR is the operational validation procurement teams need. It supports the business case for in-house defence 3D printing. For workflows without the need for the Factor 4's industrial chamber, the UltiMaker S8 and UltiMaker S6 are smaller-build alternatives. Both share the same materials ecosystem.

Defence Industry Development Grants frame the procurement context for this equipment in Australia. The Department of Defence's sovereign industrial capability priorities sit alongside these grants. For local pricing on the Factor 4 and the supporting PET CF and Tough PLA materials, request a quote directly with Australian 3D Printers. Broader Australian pricing context sits in our 3D Printer Cost Australia guide.

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Frequently Asked Questions

What is the UltiMaker Factor 4 used for in defence 3D printing?

Australian Navy operators use the UltiMaker Factor 4 inside the DAMR container to produce precise, dual-filament parts during deployments. Roles during Exercise Talisman Sabre 2025 included communication switches, drone controllers, fan brackets, and ground pegs. The team also produced a communications box exoskeleton for United States forces.

What materials can the Factor 4 print for defence applications?

Engineering polymers including Tough PLA, PETG, PA, and PET CF carbon-fibre composite all print on the UltiMaker Factor 4. Dual filament output supports soluble or breakaway support materials. The pairing prints overhangs, internal channels, and complex geometries where single-extruder machines fall short.

What is the Australian Navy's DAMR project?

DAMR stands for Deployable Additive Manufacturing and Repair Capability. It is the first prototype within the Fleet Additive Manufacturing and Repair Capability Project. Navy Logistics and Infrastructure Branch (NLIB) sponsors the project and the Navy Minor Capital Program manages it. The DAMR container houses three 3D printers and a 3D scanner to support deployed maritime units.

Why did the Navy choose the UltiMaker Factor 4 for DAMR?

Precision and dual-filament output drove the Navy's selection. The Factor 4 produces final-grade engineering parts inside a controlled build chamber. The setup suits the deployable container environment and the variety of repair and prototyping work the DAMR team handles.

Where can Australian defence buyers source the UltiMaker Factor 4?

Australian defence engineering teams, contractors, and sovereign manufacturers source the UltiMaker Factor 4 through Australian 3D Printers, the authorised local reseller. Local pricing, lead times, and supporting material packages are available on request.

What other 3D printers does the Navy use alongside the Factor 4?

Alongside the Factor 4, the DAMR container houses a Prusa Core One and a Markforged X7. Prusa Core One handles fast single-polymer prototyping. Markforged X7 prints proprietary carbon-reinforced polymer parts. A Fusion F3 will join the fleet later in 2025, bringing the DAMR to four printers in total.

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This article draws on reporting by the Australian Department of Defence: Navy prints solutions to operational problems (8 August 2025).

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3D Printer 3D Printer Accessories 3D Printers Case Study DAMR Defence Factor 4 Manufacturing Prototyping Royal Australian Navy Talisman Sabre UltiMaker