Phillips Corporation, Federal Division (Phillips Federal), has strengthened the US Navy’s advanced manufacturing capabilities by delivering a new set of hybrid and additive manufacturing systems to the Navy’s Schoolhouse in Danville, Virginia. The project, carried out in partnership with BlueForge Alliance, will equip sailors with practical training in advanced manufacturing technologies that support fleet maintenance, repairs and operational readiness.
The latest deployment includes 12 Phillips Hybrid Manufacturing Systems and 12 Markforged X7 composite additive manufacturing systems, creating a comprehensive training environment for the Navy’s Afloat Training Program. The initiative is designed to prepare personnel with the skills required to manufacture, repair and maintain critical components using modern production technologies.
At the heart of the installation are Phillips Hybrid systems built on Haas TM-1P CNC platforms and integrated with Meltio’s Directed Energy Deposition (DED) technology. These systems combine precision machining and metal additive manufacturing within a single platform, allowing operators to produce new components, restore worn parts and repair high-value equipment while using material only where it is required.
The hybrid manufacturing approach improves production flexibility, reduces material waste and shortens manufacturing lead times compared to conventional methods. Sailors will gain hands-on experience in producing mission-critical parts for fleet sustainment, depot maintenance and expeditionary operations using production-ready technologies already being introduced across the Navy.
Complementing the hybrid systems are 12 Markforged X7 composite additive manufacturing systems, which provide advanced 3D printing capabilities for producing durable composite components, prototypes, fixtures, tooling and replacement parts. Together, the two technologies expose trainees to a wide range of manufacturing techniques that support both shipboard and shore-based maintenance operations.
The new facility replicates the advanced manufacturing environment increasingly being deployed across the US Navy, enabling personnel to develop practical skills before they are assigned to operational units. By learning to manufacture and repair parts closer to the point of need, sailors will be better prepared to support fleet operations, improve equipment availability and reduce dependence on traditional supply chains. BlueForge Alliance managed the procurement process on behalf of the U.S. Navy, working closely with Phillips Federal to deliver a standardised manufacturing solution aligned with the Navy’s long-term workforce development and fleet sustainment objectives.
The project also supports the Navy’s broader Deployed Advanced Manufacturing initiative, which focuses on enabling on-site production of metal and polymer components for ships and maintenance facilities. Successful applications of additive manufacturing aboard naval vessels have demonstrated the value of producing replacement parts quickly during deployments, reinforcing the need for specialised training before personnel enter active service. The Navy Schoolhouse is owned by the Naval Sea Systems Command (NAVSEA) and operated in collaboration with the Institute for Advanced Learning and Research (IALR).
Commenting on the initiative, Bobby Keithley, Vice President of Sales and Product Strategy at Phillips Federal, said the programme reflects close collaboration between the Navy, BlueForge Alliance, Meltio, Markforged and Phillips Federal. He noted that providing sailors with training on the same advanced manufacturing systems used in operational environments will strengthen fleet readiness, improve maintenance capabilities and develop a highly skilled manufacturing workforce.
Gabriel Ortiz, Americas Channel Manager at Meltio, said advanced manufacturing technologies will play an increasingly important role in supporting naval operations. He added that equipping sailors with these capabilities will help ensure critical components can be produced or repaired whenever and wherever they are needed, improving operational efficiency and mission readiness.
Through this initiative, Phillips Federal continues to expand the adoption of advanced manufacturing technologies across defence applications, supporting the US Navy’s efforts to build a modern, resilient and highly capable maintenance ecosystem for the future.
