Byung Hee Kim, lead for the Science and Technology Directorate’s (S&T) Response and Defeat Operations Support (REDOPS) Program, shares how S&T and the Bureau of Alcohol, Tobacco, Firearms and Explosives (ATF) convened experts to share best practices for establishing agency 3D-printing programs and improve interagency collaboration.
More than 40 representatives of U.S. military, federal, state, and local government agencies, as well as international counter-improvised explosive device experts attended the February 2025 workshop. The goal of the event, co-hosted by REDOPS, was to foster collaboration in the development and use of 3D-printed tools.
Organizations with established 3D-printing programs briefed their respective efforts, shared print files for their tools, and sought opportunities to collaborate with each other. Presenters also showcased the growing impact that 3D-printed technologies are having on first responders using them in the field. This included demonstrations of rapid design and production of training aids, replacement parts for broken tools printed at a fraction of their manufactured price, and the fabrication of equipment mockups that allow training and practice repetitions without the risk of damaging operational equipment.
One notable presentation by the Rhode Island Fire Marshall’s office highlighted the creation of a rotating stand for an explosive disrupter (shown right). This unique stand enables its users to precisely and safely deploy the technology and maximize its effectiveness in the field by easily aiming the explosive effects at a target without overcomplicating the tool setup with tape, zip ties, or other improvised methods of emplacement. Another presentation by the Michigan State Police (MSP) Bomb Squad discussed their initiatives to support other activities within the MSP. MSP’s SWAT unit recognized the success of the bomb squad’s efforts to produce effective 3D printed solutions and requested support from them. So far, the bomb squad has printed training suppressors, flashlight covers, and helmet-mounted battery holders for night vision goggles used in local SWAT team field operations.
It was clear from the discussions and show-and-tell that a lack of formal education in design and printing techniques presents a significant barrier to the broader adoption of 3D-printing across the law enforcement community. To bridge this gap in the short term, more than 40 resources, including internet tutorials and other educational materials, were made accessible for beginners. In addition, ATF and the Federal Bureau of Investigations briefed attendees on 3D-printing portals available to U.S. and international first responders to foster collaboration.
Participants noted that they enjoyed the opportunity to collaborate in-person and that the workshop provided them with valuable information to help improve their 3D-printing capabilities. Additionally, the workshop culminated with the success of a nearly 2-year effort by DHS S&T for interagency collaboration on 3D printed solutions. ATF’s NCETR staff assisted in setting up a secure file sharing and collaboration portal for the workshop participants after learning of the requirements and requests identified by previous 3D printing workshops. DHS S&T will continue to support and moderate the testing of this portal until it has matured for operational use.