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Updated: Nov 6, 2025

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Hybrid Printing for the Fabrication of Smart Sensors
Published on: January 31, 2019
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Additive Manufacturing of Sensors for Military Monitoring Applications.
David T Bird1,2, Nuggehalli M Ravindra2,3
1Picatinny Arsenal, NJ U.S. Army Combat Capabilities Development Command Armaments Center (CCDC AC), Wharton, NJ 07885, USA.
Polymers
|May 5, 2021
Summary
Additive manufacturing (AM) enables 3D printed sensors for warfighter protection, offering real-time physiological monitoring. Further research into AM techniques is needed for enhanced soldier safety and battlefield effectiveness.
Area of Science:
- Engineering
- Materials Science
- Defense Technology
Background:
- Additive manufacturing (AM) is a key fabrication technique across industries.
- 3D printed (3DP) sensors offer advanced capabilities for warfighter support.
- Current AM needs include higher resolution, efficiency, and faster print times.
Purpose of the Study:
- To review and compare various 3D printing techniques for sensor fabrication.
- To highlight the potential of 3DP sensors for warfighter protection and situational awareness.
- To identify areas for AM advancement in defense applications.
Main Methods:
- Review of existing additive manufacturing technologies for sensor production.
- Comparative analysis of different 3DP techniques based on performance metrics.
- Literature synthesis on the application of 3DP sensors in defense.
Main Results:
- 3DP sensors provide high-performance features for real-time warfighter monitoring.
- AM offers enhanced protection against battlefield threats like toxins and pathogens.
- Optimized AM fabrication can improve sensor performance, sensitivity, and speed.
Conclusions:
- Additive manufacturing is crucial for developing advanced 3D printed sensors for defense.
- Further exploration of AM is essential to enhance warfighter safety and lethality.
- Optimizing 3DP techniques will lead to superior sensor performance for military applications.

