Case Study: US Naval Undersea Warfare Center achieves 43-week lead-time reduction and 40% cost savings with ExOne

Reverse Engineer Compressor Pump Castings with 43 Week Reduction in Lead Time and 40% Cost Savings

US Naval Undersea Warfare Center (NUWC) – Keyport needed vacuum cone castings for Ohio‑class submarines but had none in its supply system; the OEM quoted $29,562 each with a 51‑week lead time. ExOne was engaged to provide an alternative using its additive manufacturing/sand printing (digital part materialization) process.

Using CAD files created from NUWC Keyport’s reverse engineering, ExOne printed sand mold packages and enabled final castings to be delivered in 8 weeks at $18,200 each — a 43‑week lead‑time reduction and roughly 40% cost savings versus the OEM. ExOne’s process produced accurate molds rapidly for the 4‑part batch, delivering measurable time and cost improvements.

US Naval Undersea Warfare Center