One standout achievement involved a deceptively simple but mission-critical component: anti-reflective “killflash” devices for weapon optics. These covers eliminate lens glint that can compromise a Marine’s position while protecting sensitive optics in combat. 

Prior to the exercise, the Marine Corps faced a 59-day back-order delay for these parts. Using the EOS P 396 polymer system, Phillips Federal and Marines produced more than 400 killflash units onsite in just two days—at approximately $3 per part. The effort delivered over $25,000 in direct savings and a substantial increase in operational readiness. 

Strength in Metal, Scale, and Expeditionary Innovation 

Throughout the exercise, Phillips Federal showcased the complementary strengths of multiple cutting-edge platforms from EOS, Markforged, and BigRep, each delivering unique capabilities tailored to specific materials and operational demands. 

• The EOS M 290 metal system rapidly produced high-performance components under tight timelines, including 36 M4 swivel mounts in just 10 hours, along with TPS-80 G/ATOR radar carrier plates and PAWL compression latch camshafts. These durable, field-ready metal parts highlighted additive manufacturing’s ability to deliver robust solutions when traditional supply chains cannot. 

• The Markforged X7 systems powered an innovative “Drone Farm” — six printers housed in a fully air-mobile ISU-90 containerized unit. During the exercise, the farm produced three First Person View (FPV) drones using Onyx chopped carbon fiber material. Lightweight yet extremely durable, the drones were fully designed, printed, assembled, and flown in the field. The complete process took approximately 14 hours of print time and one hour of assembly, proving the speed and adaptability of additive manufacturing for unmanned systems at the tactical edge. 

• The large-format BigRep VIIO 250 delivered oversized, high-value components with exceptional efficiency. It produced three TPS-80 G/ATOR radar receptacle covers in just 8.5 hours and 12 sand pad storage brackets. Most notably, it manufactured two radar carrier plates with a combined assembly value exceeding $22,250, delivering major cost and lead-time savings.