Dynovas’ Expeditionary FOAM Pod Reaches Major Development Milestones

San Diego, CA, September 2025 — Dynovas proudly announces two major developmental milestones for its Field Optimized Advanced Manufacturing (FOAM) Pod, a next-generation, expeditionary 3D metal printing system designed for rapid, field-ready deployment.

Over the past year, the FOAM Pod successfully completed MIL-STD-810H ruggedization testing and participated in Trident Warrior 2025, the largest additive manufacturing demonstration ever conducted by the U.S. Department of Defense (DoD). As a result, the system now stands as a fully operational Technology Readiness Level 7 (TRL7) prototype, ready for real-world application.

FOAM Pod in Packed/ Deployed State

Key Features of the FOAM Pod

·       Packaged in a 20’ CONEX container format

·       Expandable “fold-out” side walls and roof/floor, tripling the workspace in under 45 minutes

·       Approx. 16,500 lbs with balanced center of gravity for transportability

·       Capable of producing 3D metal parts up to 10” x 10” x 10” in just days

·       Designed for simplicity, safety, and field repairability

·       MIL-STD-810H validated for tactical operations

In March of 2025, the FOAM Pod traveled out to Nevada Automotive Test Center (NATC) to begin assessments to MIL-STD-810H testing for on road transport, off road transport, flat drop, and angle drop full-system testing. The ruggedization and system hardening testing took place over three weeks, with intermittent validation of equipment performance between the individual tests. Testing was completed and marked a success with the arrival of the FOAM Pod back at Dynovas’ facilities and the immediate restart of manufacturing hardware via the 3D metals process.

Off-Road Testing of FOAM Pod

Dynovas’ FOAM Pod achieved another major milestone this summer through full participation in Trident Warrior 2025, the Navy’s premier fleet experimentation exercise. Conducted at Naval Base North Island’s Fleet Readiness Center, the event represented the largest additive manufacturing demonstration held to date within the DoD, with Dynovas as the only onsite industry participant for the full exercise. Throughout the event, Dynovas engineers and operators worked alongside Naval Postgraduate School, Consortium for Advanced Manufacturing Research & Education (CAMRE), and the Marine Innovation Unit (MIU) partners to demonstrate point-of-need metals manufacturing for sustainment and repair applications.  This major milestone was further highlighted by Fox News in an article about cutting edge military technology.

Fox News Interview of 2025 Trident Warrior Exercise

The FOAM Pod was successfully deployed as a fully operational TRL7 prototype producing 5 unique part types. The insights from Navy fleet maintainers, operators, and leadership will guide the next phase of technical maturation and transition planning as Dynovas continues to partner with the Navy to provide resilient, deployable manufacturing capabilities that strengthen contested logistics and fleet readiness.

Parts Manufactured by FOAM Pod