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A Northern Territory-led research effort is set to transform how Australia produces a key naval material, with scientists turning to high-speed 3D printing to manufacture components traditionally considered difficult and slow to make.
Researchers from Charles Darwin University (CDU) are leading a new project focused on nickel aluminium bronze (NAB), a critical alloy widely used in naval propulsion systems but increasingly challenging to produce domestically.
Backed by funding from the Queensland Defence Science Alliance (QDSA), the initiative brings together a cross-sector team, including James Cook University, the Australian Institute of Marine Science, and advanced manufacturing firm SPEE3D.
NAB is prized for its strength, durability and corrosion resistance, making it a staple in marine propellers, submarine components, pumps, valves and other high-performance applications. Despite its widespread use, traditional manufacturing methods for NAB are no longer considered viable in Australia, creating a potential supply chain vulnerability.
The project aims to overcome this by using SPEE3D’s cold spray additive manufacturing process to rapidly produce NAB components. These parts will then be tested in tropical seawater conditions to assess their durability and performance.
Lead researcher, CDU Professor Kannnoorpatti Krishnan, said the work addresses a pressing need for resilient, corrosion-resistant materials for the Australian Defence Force: “This approach reduces downtime, improves resilience at forward operating bases and supports operational effectiveness in contested maritime environments.”
He added the research would also generate new insights into how such materials behave in Pacific waters, where microbial environments remain largely unstudied.
Beyond defence applications, the project is expected to strengthen Australia’s sovereign industrial capability by building a localised supply chain that combines deployable manufacturing systems with expertise in materials science, chemistry and marine research.
QDSA director Stuart Blackwell said the collaboration between Queensland and the Northern Territory highlighted the growing importance of littoral and maritime innovation.
“Producing critical maritime components closer to where they’re needed, and on demand, represents a major shift in how we approach logistics and sustainment,” he said.
SPEE3D, which claims to be the only company capable of producing an NAB-equivalent material using its cold spray process, sees significant potential in the technology.
Co-founder and chief technology officer Steven Camilleri said the approach could reshape maintenance and repair operations across the Indo-Pacific, adding: “If we can demonstrate equivalence to traditionally cast NAB, this isn’t just a novel capability – it’s the recovery of a strategically important material.
“Additive manufacturing means parts can be produced faster, closer to the point of need and with far greater control.”
Researchers from James Cook University will contribute expertise in alloy composition and corrosion analysis, including studying how rare earth elements can enhance NAB performance. Testing will be carried out using advanced simulation systems at the Australian Institute of Marine Science’s National Sea Simulator (SeaSim) in Townsville, as well as in nearby coastal waters.
SeaSim director Craig Humphrey said the facility’s ability to replicate complex marine conditions such as variations in temperature, salinity, pH and water flow would be critical to understanding how the materials perform in real-world environments.
Stephen Kuper
Steve has an extensive career across government, defence industry and advocacy, having previously worked for cabinet ministers at both Federal and State levels.
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