The Jointless Hull project, led by LJ Holmes and the STORMWERX Research Center in collaboration with the US Army Corps of Engineers, represents a significant breakthrough in military vehicle manufacturing. By leveraging metal AM (additive manufacturing), this initiative aims to produce ground vehicle hulls as single, monolithic structures, eliminating the joints and welds that have historically been weak points in combat vehicles. These innovations are designed to enhance production efficiency, reduce costs, and ultimately create lighter, more stable vehicles that are better able to withstand underbody blast events, such as IEDs and roadside bombs.

Since the Vietnam War, many vehicle losses have been linked to failures at welded joints. The Jointless Hull machine – the world’s largest metal hybrid manufacturing system – addresses this by enabling the production of jointless vehicle hulls, significantly improving durability in harsh combat environments. This groundbreaking technology has won several technical achievement awards, and its development was made possible through collaborative efforts and Congressional funding secured by Holmes and ASTRO America. The project marks a major step forward in the US Army’s efforts to protect its vehicles and personnel on the battlefield.

The Cooperative Research and Development Agreement (CRADA) between STORMWERX and the Naval Information Warfare Center (NIWC) is a key collaboration aimed at advancing the application of additive manufacturing within the Naval enterprise. Through this partnership, STORMWERX works closely with Navy scientists and engineers to identify critical use cases and implement cutting-edge manufacturing solutions at Marine Corps installations. The focus is on enhancing operational capabilities and addressing specific challenges through advanced technologies.

This agreement aligns with the strategic objectives of the Secretary of the Navy, the Commandant of the Marine Corps, and the Chief of Naval Operations. By integrating additive manufacturing into the broader Naval enterprise, the CRADA supports efforts to strengthen the Marines’ readiness, reduce logistical barriers, and deliver next-generation capabilities across the force.

Harrisburg University (HU) is currently engaged in a Cooperative Research and Development Agreement (CRADA) with the US Navy, aimed at advancing reverse engineering, repair, and re-manufacturing techniques to meet the needs of both the Navy and the Marine Corps. This collaboration provides a platform for Marines and Seamen to bring forward innovative ideas, which are then developed into prototypes at HU. Through comprehensive testing and evaluation, these concepts are transformed into practical solutions that support mission-critical objectives for the Navy and USMC.

In addition, HU has a CRADA with the US Army that spans collaboration across all US Army DEVCOM laboratories, including the Armaments Center, Army Research Laboratory, Aviation & Missile Center, C5ISR Center, and more. This agreement focuses on material and process development to broaden the applications of advanced manufacturing technologies. By gathering crucial data, this partnership is helping to drive the transition of these technologies into operational use, supporting the Army’s efforts to enhance its capabilities and modernize its processes.

In collaboration with heart surgeons from UPMC, this project utilizes advanced medical imaging and 3D printing to support pre-surgical planning. The surgeons provide a series of DICOM files, generated from MRI scans of a patient’s heart, which are then used to create a highly accurate digital twin of the heart. This digital model allows for precise analysis of the patient’s unique anatomy.

The STORMWERX team then uses these digital twins to produce several anatomically correct 3D-printed models of the heart, which surgeons can use to enhance their preoperative preparation. These models enable the surgical team to better understand the patient’s condition and plan more effectively, ultimately improving outcomes and reducing risks during surgery.