Finland-based miniFactory’s technology enables production of complex ducting components for one of the United Kingdom’s most important defence modernisation programmes.

Rheinmetall UK has confirmed that industrial 3D printing, also known as additive manufacturing, is now the baseline production method for complex ducting components within the Challenger 3 Main Battle Tank programme.

The achievement marks a significant step in the adoption of industrial 3D printing within defence manufacturing. While many organisations continue to evaluate the technology for prototyping and development work, Rheinmetall UK has successfully transitioned it into production.

Following an extensive evaluation of manufacturing technologies, materials and production approaches, Rheinmetall UK selected the miniFactory Ignite platform to establish an in-house manufacturing capability. The system is specifically designed for demanding high-performance polymers and composite materials used in aerospace, defence and industrial applications.

For this application, Rheinmetall UK selected ULTEM™ 9085, a high-performance material widely used in demanding environments where mechanical performance, flame retardancy and reliability are critical.

The objective was not simply to introduce a new manufacturing technology, but to create a flexible production capability capable of supporting complex geometries, rapid design iterations and evolving programme requirements without the costs, lead times and risks associated with traditional tooling.

Today, industrial 3D printing is the baseline manufacturing method for these components.

By bringing production capability in-house, Rheinmetall UK can rapidly implement design changes and manufacture replacement components within a single day. Tooling requirements have been eliminated, inventory levels reduced and production can be aligned directly with programme needs. The result is improved responsiveness, lower programme risk and significant cash-flow benefits through on-demand manufacturing.

“Additive Manufacturing is now the baseline solution for ducting manufacture in the Challenger 3 programme. The technology has enabled rapid design iteration, allowing us to implement design changes and produce replacement parts within a day. Beyond cost savings, the biggest benefits have come from reduced programme risk, improved cash flow through on-demand production, and the ability to continuously optimise both the product and the manufacturing process.”

Julian Wright, Technology Programmes Manager, Rheinmetall UK

The project reflects a broader trend across the defence sector. As European nations continue investing in military readiness and industrial capacity, manufacturers are increasingly looking for technologies that improve agility, strengthen supply-chain resilience and reduce dependency on lengthy procurement cycles.

For Finland-based miniFactory, the project demonstrates how industrial 3D printing delivers the greatest value when implemented as part of a manufacturing strategy rather than as a standalone technology investment.

“The real success story is not the printer. The success story is that additive manufacturing is now delivering measurable value in production for one of the UK’s most important defence programmes. Success comes from understanding the customer’s challenges and building the right manufacturing solution together. When adoption happens the right way, the results speak for themselves.”

Riku Hietarinta, Chief Development Officer, miniFactory

What started as the evaluation of a single application has evolved into a production capability supporting one of the United Kingdom’s most important defence programmes. The Challenger 3 programme demonstrates that industrial 3D printing is no longer a future capability being evaluated by defence organisations—it is already delivering measurable value in production today.

About miniFactory

miniFactory is a Finnish manufacturer of industrial 3D printing systems headquartered in Finland. The company’s technology specialises in processing high-performance polymers and composite materials for demanding defence, aerospace, rail and industrial applications where reliability, traceability and material performance are critical.

Main image: Challenger 3 main battle tank, Ministry of Defence © Crown copyright 2026. Used under the MOD News Licence.