Retired Gen. Edward M. Daly, CEO of DALY Consulting & Logistics and former commanding general of the U.S. Army Material Command; D. Mark Douglass, PhD, CFA, business development manager at Lincoln Electric Additive Solutions; Dr. Zack McClelland, research mechanical engineer at the U.S. Army Engineer Research and Development Center Geotechnical and Structures Laboratory; and Thomas Engelman, senior partner at Defense Strategies Institute, pose for a photo after Douglass and McClelland accepted the Technical Achievement Award for 3D Printing Innovation at the Military Additive Manufacturing Summit & Technology Showcase in Orlando, Florida. The award recognizes Lincoln Electric and the U.S. Army Corps of Engineers for their use of large-scale 3D printing to restore critical U.S. infrastructure. (Photo courtesy of Defense Strategies Institute)

Established in 2021, the award recognizes individuals and organizations for significant contributions to additive manufacturing research, development, and implementation to support the defense industrial base. The DSI advisory board selects winners based on the innovation and impact of their work in supporting Department of Defense mission priorities and enhancing military and industrial readiness. Lincoln Electric and its partners were recognized for their use of large-scale 3D metal printing technology in lieu of casting to produce a replacement part for a ship arrestor system at the Poe Lock, a vital part of one of the nation’s most important shipping routes.

When cracks were discovered in the 60-year-old ship arrestor system’s 14-foot-long lever arm, traditional manufacturing methods would have required up to 18 months to produce a replacement, potentially disrupting normal operations. A major transit point for domestic iron ore, an unanticipated Poe Lock closure would be “catastrophic for the nation,” according to a 2015 Department of Homeland Security (DHS) study.

According to the study, a six-month closure would temporarily reduce the U.S. gross domestic product by $1.1 trillion, resulting in the loss of 11 million jobs.

In response to the urgent need, USACE and ERDC partnered with Lincoln Electric to produce a replacement part using the company’s proprietary large-scale 3D metal printing technology. Lincoln Electric produced the steel lever arm in just three months—an 84% reduction in lead time. This allowed for timely installation during the scheduled winter maintenance window, avoiding an extended closure of the Poe Lock. The replacement part is the largest U.S. civil works component produced with 3D printing.

“The Poe Lock arrestor arm really shows what can be done with technology in terms of complex designs, and it signals a paradigm shift in how large parts can be manufactured," said Dr. Zack McClelland, research mechanical engineer at ERDC’s Geotechnical and Structures Laboratory.

About Lincoln Electric

Lincoln Electric is the world leader in the engineering, design, and manufacturing of advanced arc welding solutions, automated joining, assembly and cutting systems, plasma and oxy-fuel cutting equipment, and has a leading global position in brazing and soldering alloys. Lincoln is recognized as the Welding Expert™ for its leading materials science, software development, automation engineering, and application expertise, which advance customers’ fabrication capabilities to help them build a better world. Headquartered in Cleveland, Ohio, Lincoln operates 71 manufacturing and automation system integration locations across 20 countries and maintains a worldwide network of distributors and sales offices serving customers in over 160 countries. For more information about Lincoln Electric and its products and services, visit the Company’s website at www.lincolnelectric.com.