Advancing Additive Manufacturing in Defense with MIL-STD-810

Military Specification (MIL-SPEC) testing is critical in ensuring the reliability of additive components used in defense. It forms the backbone of quality assurance for systems used across the armed forces, with individual standards defining uniform engineering requirements for processes and procedures —such as MIL-STD-810 for environmental testing. 

As additive manufacturing (AM), particularly metal 3D printing, continues to mature, its role in defense applications is rapidly expanding. Yet integrating AM solutions into military supply chains presents unique challenges—particularly when aligning with established MIL-SPEC protocols.

This article explores how MIL-SPEC testing intersects with additive manufacturing, the evolving standards landscape, and how industry innovation is helping to bridge the gap between cutting-edge production and proven reliability. 

Understanding MIL-SPEC Testing

MIL-SPEC is an umbrella term, typically referring to a comprehensive set of technical documents used by the U.S. Department of Defense (DoD) to standardize the design, manufacturing, testing, and performance of military equipment and systems.  

One of the most widely recognized standards is MIL-STD-810, which is used to evaluate environmental durability. This standard is particularly relevant for mechanical and electronic subsystems in vehicles, drones, aircraft, and battlefield equipment. The MIL-STD-810 test series are approved for use by all departments and agencies in the United States.  It is the most common standard we come across when referencing MIL-SPEC.  However whilst MIL-STD-810 is a US standard, it has been widely adopted by international militaries to ensure reliability, optimal performance and interoperability.

Successfully navigating these test protocols is essential for any component intended for mission-critical defense settings.
 

MIL-STD-810 includes rigorous testing for:  

• Temperature extremes and thermal cycling: Assessing functionality in both high heat and freezing conditions. 

• Low pressure and high-altitude conditions. 

• Shock and Vibration: Evaluating resilience against impacts and constant motion. 

• Humidity and Corrosion: Testing resistance to moisture and salt fog exposure. 

• Sand and Dust: Ensuring seals protect against fine particles that could compromise performance. 

• Explosive atmospheres and electromagnetic disturbance. 

These tailored testing protocols validate the reliability of AM products for deployment in harsh environments. While initially developed for military applications, MIL-STD-810 has been widely adopted across industries like oil and gas, mining, and pharmaceuticals due to its rigorous testing protocols.

Certified to AS9100D, Quality Assurance is engrained throughout the Conflux process. Source: Conflux

Additive Manufacturing Meets MIL-SPEC Standards

Additive manufacturing is reshaping defense production through its benefits and innovations such as; rapid prototyping, on-demand manufacturing, and localized production. Metal AM brings unprecedented design flexibility, rapid prototyping capability, and the ability to produce complex internal geometries that would be impossible with traditional methods. These benefits are particularly compelling for aerospace, unmanned systems, and thermal management components where weight, efficiency, and part consolidation are critical. 

The challenges facing AM parts in defense are not unlike those in other industries: how to test, qualify, and certify a newer manufacturing process with less historical data, and how to maintain the speed advantages of AM without then experiencing delays during testing.

Aligning these novel manufacturing approaches with legacy qualification processes introduces complexity. For example:

• Standards for AM are not yet universally defined across all defense branches, leading to inconsistency in evaluation criteria. 

• Data scarcity for long-term performance in operational environments can slow acceptance, even when lab results are strong due to the difficult process of trying to recreate exact conditions in theatre. 

• Qualification of parts often takes longer for AM because, while the components may be developed faster, the relative immaturity of the technology means there is less existing qualification data to rely on.
   

Despite these hurdles, significant progress is being made—both in refining test methods and in adjusting regulatory frameworks to better accommodate AM technologies. 

MIL-SPEC testing remains the foundation of trust in defense-grade components. Source: Bautista, Pexels.com

Advancements and Innovation in AM Testing for Defense Applications 

As an additive manufacturing innovator, Conflux is actively supporting the evolving needs of multiple sectors. Our proactive approach to overcoming component-level challenges has led to significant investment in advanced testing and the development of unique, data-driven validation strategies—delivered in collaboration with our key partners and clients.
 

Advanced Testing Methods

Non-Destructive Testing (NDT) and inspection techniques allow us to assess the properties, integrity, and functionality of materials, components, and systems without causing damage or altering the structure of our thermal solutions. We utilize widely recognized methods such as X-ray computed tomography (CT) scanning.

Taking this a step further, our collaboration with the Australian Nuclear Science and Technology Organisation (ANSTO) represents a breakthrough in inspection capability, using the Australian Synchrotron (a high-energy particle accelerator) to reveal sub-macroscopic structural features that are otherwise invisible. These insights enable an incredible inspection capability for the ultra-thin walls found in our heat exchangers.  It also informs both material selection and process control, strengthening the scientific basis for AM qualification. 
 

Data-driven Qualification Approach 

Conflux continues building extensive digital databases of material and performance data, enabling faster qualification cycles through validated, repeatable benchmarks. This shift toward data-driven qualification aligns closely with DoD’s objectives under recent defense strategies and budget frameworks. By leveraging modelling and simulation, providing empirical evidence of a part’s validity can work towards streamlining the qualification process. 

Data underpins the advancement of qualification processes. Source: Stool Icon by Lars Meiertoberens from the Noun Project

Evolving Standards and DoD Reform: A Path Forward for Additive Manufacturing 

The synergy between AM and MIL-SPEC testing is poised to redefine defense capabilities. By combining the flexibility of AM with the robustness ensured by MIL-STD-810 compliance, military forces can achieve new levels of readiness and efficiency.  With the global military 3D printing market projected to reach $7.5 billion by 2031, the role of standardized, reliable testing frameworks will remain essential.

As the defense sector evolves, legacy protocols are being redefined to better accommodate agile manufacturing. Emerging technologies are proving their value not just in the lab, but in the field.

Recognizing the need for modernization, the DoD has initiated ongoing reforms aimed at reducing reliance on overly prescriptive, military-unique standards in favor of performance-based and commercial specifications.

Key outcomes include: 

Performance-based criteria: A shift from “how” a part is made to “how well” it performs—opening the door to AM’s design freedom. 

Digital thread and data sharing frameworks: Supporting iterative design and simulation-based validation techniques. 

Greater supply chain flexibility: AM’s ability to produce parts on-demand simplifies logistics and supports localized manufacturing—especially for legacy systems or austere environments.

These efforts are creating a more dynamic testing and compliance landscape that allows emerging technologies like AM to play a more significant role. Additive manufacturing is not just adapting to defense—it’s helping to shape its future.

Aligning innovative design methods with robust qualification processes is key to realizing the full potential of AM in military applications, unlocking smarter, lighter, and more capable solutions for defense systems of tomorrow.