As America’s civil works infrastructure ages, managers need innovative solutions to replace parts that have been in service for nearly a century. Often, these original components were fabricated using vintage material and manufacturing methods, making them costly, burdensome and time-consuming to replace.
Responding to this need, the U.S. Army Corps of Engineers (USACE) is employing cutting-edge 3D printing techniques to manufacture these parts faster and at a lower cost while maintaining, and even improving, their properties.
In early March, the USACE Detroit District installed the largest U.S. civil works infrastructure component produced by a 3D printer – a 12-foot-long metal part for the ship arrestor system on the Poe Lock, one of the two active locks on the Soo Locks facility. Building on years of research performed by the U.S. Army Engineer Research and Development Center (ERDC), the part was manufactured in 12 weeks, compared to a projected 18-month lead time for conventional manufacturing. The part was installed, tested and commissioned during the Soo Locks’ winter maintenance cycle.
The rapid repair ensured normal operations at Poe Lock, a major transit point for domestic iron ore.