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Defence Manufacturing Solution
Advanced Manufacturing

Advanced Manufacturing Technology

We provide advanced manufacturing services in technologies like 3d printing, CNC machining, vacuum casting, injection molding, laser cutting, etc.

On Time Project Delivery

on time project delivery

With locations in all over Australia we can assure lightning fast delivery.

Australia Wide Expandation

Australia wide expandation

Zeal 3D is present in
Victoria, NSW, Western Australia,
Queensland and Tasmania.

Experienced Engineers

Team of expert engineers with more than 15 years of experience.

How Does Zeal 3D Help the Defence Industry by offering 3D engineering services?

One-Stop Solution: At Zeal 3D, you can find solutions to everything from 3D designing to rapid prototyping and mass manufacturing services, thereby putting an end to your search for the best 3D engineering services in Australia.

High-end Technologies: Using cutting-edge 3D engineering technologies, Zeal 3D can manufacture defence and military equipment in a variety of metals, regardless of how intricate the design.

Customized Services: Zeal 3D provides specialised 3D engineering services that can be tailored to your exact needs and even the smallest details.

Increased Material Support: Depending on the demands and objectives of the client, we operate with a wide variety of over 45+ materials in order to achieve reliable products with high precision tolerances.

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No MOQ Needed: Even if you need manufacturing services with elements not on our material list, our staff will make all the necessary efforts to obtain the materials without needing a minimum order quantity (MOQ).

Manufacture At Any Scale: Zeal 3D helps companies produce tools or equipment of any size and scope (1–10,000 pieces) for high or low volume production at the most affordable price.

Australia Wide Fastest Delivery: Zeal 3D provides the quickest delivery options across Australia, including Sydney, Brisbane, Perth, Tasmania, Melbourne, Canberra, Adelaide, and New Zealand.

High Quality Assurance: Zeal 3D takes great effort to guarantee quality assurance and consistently produce high-quality products with tight tolerances in order to achieve the highest degree of client satisfaction.

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3d Printing Defence
Defence Industry 3D Printed Plastic Part

High-End Services offered by Zeal 3D for Defence Industry

3D Printing

Using cutting-edge technology such as 3D printing is nothing new in the defence and military sectors. The defence industry has been one of the forerunners in implementing additive manufacturing technologies, such as 3D printing, in recent years. The development and application of 3D printing have made it possible to produce spare parts more quickly and handle logistics more easily in the defence sector. The speedy development of working prototypes is made easier by 3D printing services, which are also a practical method for producing finished goods.

Zeal 3D Specializations:

  • At Zeal 3D, we offer affordable 3D printing services by leveraging additive manufacturing technologies like FDM, SLA, SLS, MJM, and DMLS in order to produce military equipment and components.

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    • With 3D printing technologies, we can manufacture parts for weapons and prototypes for the defence industry.
    • At Zeal 3D, we can prototype and manufacture enclosures, covers, and parts for the various equipment used in surveillance and military applications.
    • With 3D printing, we can produce complex designs that are impossible to construct using conventional manufacturing processes.
    • For training and exhibition reasons, scaled-down or life-size replicas of various systems and objects are created using 3D technology.

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CNC Machining

In the defence industry, CNC machining operations are perfect for creating missile components and other weapons due to their high level of precision, adaptability, and compatibility with a variety of materials. Adding to the fact that CNC machines have been utilized in military applications since their debut, contemporary CNC mills and drills, which are subcategories of CNC machining, also offer a unique feature that most other industrial technologies cannot match. In order to satisfy all of your unique requirements, Zeal 3D offers specialized CNC machining services employing a wide range of cutting-edge technologies, and we adhere to all international standards and specifications while implementing CNC machining.

Zeal 3D Specializations

  • Zeal 3D allows you to choose from a variety of materials for manufacturing customised end-products for the defence sector based on your business needs and applications.
  • We offer incredibly precise production for finished goods related to the defence sector.

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  • At Zeal 3D, we provide a range of post-processing services, including polishing, itching, knurling, anodizing, plating, plastic, and more.
  • We have inhouse capacity of CNC machining on 3,5 and 7 axis machines which has maximum building capacity of 1200x800x800mm.
  • We also promise quality control that meets industry norms and specifications.
  • For CNC production, there is no minimum order quantity, and we also provide CNC machining services for prototyping.
  • At Zeal 3D, we utilise a wide range of materials for CNC machining like

    Plastic and Composites

    • Nylon
    • ABS
    • HDPE
    • CFNylon
    • ULTEM


  • With the CNC machining process, we can seamlessly produce components and equipment related to the defence industry, such as PPE, assembling components, spares parts, etc.
  • At Zeal 3D, we provide mass production of the military related spares, parts or equipment using the CNC machining process.

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CNC Machining Military Defense Parts

Injection Moulding

Plastic injection moulding, which has many applications across various sectors, is one of the most widely used processes for producing plastic parts. Injection moulding is widely used in the context of military applications, where equipment must resist some of the harshest environments on earth. While offering the option to use very resilient plastic to minimise weight, the injection moulding process also assures homogeneity.
Plastic injection moulding is becoming more and more popular among DFM engineers working on military projects because of its robust material possibilities, automated production methods, and durable end products. Zeal 3D Services offers comprehensive prototyping and plastic component production services using plastic injection moulding technology. We can design and produce exceptional injection-moulded plastic components using our cutting-edge equipment, know-how, and experience.

Zeal 3D Specializations

  • To create high-end components for the defence sector, Zeal 3D offers industrial-grade materials of the highest quality.

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  • Using our cutting-edge technologies, we guarantee accuracy and a flawless surface finish.
  • We use materials from the ABS, PP, and PE grades to create end products or goods.
  • At Zeal 3D, some of the most popular materials we use for plastic injection moulding are

    • Acrylonitrile butadiene styrene (ABS)
    • Polyamide
    • Polypropylene
    • Polyvinyl chloride


Some of the Defence products that can be made with the injection moulding process are:

  • Chassis Components
  • Cabin Spares
  • Subsequent Moulds
  • Military Helmets
  • Bezels
  • Turbine housings
  • Pin maps

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Laser Cutting and Fabrication

Laser cutting is the method of choice for designs that require the highest level of repeatability and accuracy. Manufacturers can create precise components by melting or evaporating materials—typically metals—using computer-controlled, powerful lasers. All military branches use laser-cut components in a range of ground, air, and sea applications, as well as in a variety of other unique environments. This procedure is widely used in order to produce high-stress armour plates for military vehicles and missiles. At Zeal 3D, we offer efficient laser cutting services that make use of cutting-edge technologies to produce tools and equipment for the defence industry.

The process of making a product or model out of various raw materials through cutting, mixing, and assembling parts is known as fabrication technology. The defence industry relies heavily on sheet metal fabrication to create the components required for a variety of defence missions. Fabrication is frequently used in the defence sector to create military vehicle roll bars, tubes, pipe fittings, ship handrails, navy ship pallets, brackets, and fittings for various military equipment, as well as many more metal fabricated solutions.

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With the most advanced and cutting-edge technologies, Zeal 3D can fulfill all of your sheet metal manufacturing requirements. We have all the necessary equipment, industry experts, and knowledge to ensure that your projects will be as successful as possible.

Zeal 3D Specializations

  • Zeal 3D's areas of expertise include the production of end products for the defence sector using premium industrial grade materials.
  • To slice or cut a wide range of materials, we use advanced laser cutting technology.
  • We provide tailored service support depending on your company's needs and specifications.
  • At Zeal 3D, we provide services for a variety of materials, like

    • Mild steel
    • High strength steel
    • Stainless steel
    • Titanium
    • Copper
    • Bronze
    • Brass Ceramic
    • Plastic and acrylic
    • Rubber
    • Foam
    • Also, other nonferrous material Fabric


Laser cutting and fabrication services are used for variety of defence applications like

  • Military vehicle wing spares
  • Tooling parts
  • Fixture elements
  • Parts of end effectors

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Laser Cutting for Defence Industry
Aluminium Extrusion Manufacturing for Defence Sector


Extrusion is a kind of industrial manufacturing procedure that produces objects with a specified shape and cross-sectional profile. For the design and production of defence equipment and systems, extrusion has long been recognised as an important technique. Aluminium extrusions are ideally suited for manufacturing defence equipment and components due to their efficient capabilities, including corrosion resistance, versatility, ease of machining and fabrication, cost-effectiveness, and durability. At Zeal 3D, we offer four key extrusion techniques, including cold, hot, friction, and micro extrusions, to create products of varying quality by utilising a choice of metal extrusion alternatives, including aluminium and many others.

3D Designing and 3D Scanning

In the 3D designing stage, designers can create basic blueprints or CAD designs for the defence equipment that will be manufactured, including the filleting radii and minimum die angles. The CAD software automatically creates faultless surfaces that adhere to all design requirements. Additionally, CAD offers a wide range of 3D design tools and abilities for better edge blending and chamfering.

With the use of the 3D scanning technique, military organisations and defence contractors can quickly measure new or old parts, vehicles, or aircraft components for inspection, getting a blueprint of the product, or product re-creation. The military industry uses 3D scanning technology to collect product layout data and process it to make further modifications and updates, which lowers human error and guarantees deadline compliance.

Application of 3D Scanning

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  • 3D Scanning for reverse engineering.
  • To modify or develop the existing parts.
  • 3D scanning of old parts and replications
  • Inspections and analysis

Zeal 3D Specializations

  • We offer industrial high-precision 3D scanning services both on- and off-site at Zeal 3D.
  • Additionally, we provide service assistance to our clients with design and development.
  • At Zeal 3D, we offer technical assistance throughout the whole product development process, from the designing stage to the mass production of end-products or prototypes.

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Zeal 3D CAD Services
Augmented Reality for Defence

Augmented Reality

One of the first sectors to completely comprehend the range of applications that augmented reality may serve is the military. Numerous advantages of AR include increased productivity, remote support made easier, and the replacement of paper manuals with step-by-step instructions. In addition to this, AR is playing a bigger role in military training as it allows for the display of virtual assets as if they were in the actual world. Pilots and troops are now using AR on the battlefield to improve their situational awareness and response times.

Zeal 3D Specializations

  • Customised solution according to client’s needs.
  • App based, web based, and wearables based (MR) development.
  • Local trust and confidentiality.

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At Zeal, we offer augmented reality services that helps you with,

  • Visualization of scaled or life size versions of different products and systems for training and exhibition purposes.
  • Development of training programs.
  • Development of simulations.
  • Development of maintenance solutions.
  • Development of remote assistance solutions.

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Contract Manufacturing

In the defence sector, "contract manufacturing" refers to a legal arrangement between a manufacturer and defence equipment manufacturers to produce components or finished goods for defence and military purposes. As a way to reduce costs, gain access to manufacturers' knowledge and technological resources, and obtain the quality assurance they want for their products, companies are turning more and more to contract manufacturing of defence equipment and products.

Metal 3D Printed Defence Parts
Aerospace 3D Printing

Areas Of Defence We Offer 3D Engineering Services

Military: The most significant benefit of using 3D engineering technology in the military sector over conventional manufacturing processes is that it aids in the development of spare parts, enabling extremely effective maintenance and repair of military defence systems. Utilizing 3D engineering services for military applications adds even more specific standards and requirements. The reverse engineering services can be used to create original or replacement parts as well as prototypes. In addition, rapid prototyping has an impact on military logistics by influencing how quickly components can be delivered to the battlefield at the appropriate time.

Navy: In the naval sector, 3D engineering technologies are often used to manufacture spare parts for military ships and submarines. It is also used in making PPE for marine soldiers, marine engines, compressors, turbo changer, propeller shafts, compact seals, and much more by leveraging appropriate 3D engineering services like CNC machining, vacuum casting, 3D printing, and injection moulding.

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Airforce: Over a decade ago, 3D engineering technology started to play a role in the manufacture of interior aircraft parts in the air force sector. With the use of 3D engineering services, it is now possible to produce intricate geometries and organic designs that are lighter for air ducts, wall panels, and seat frameworks. Large interior components for aircraft commonly employ 3D printing as a master template because it is quicker and better equipped to create complicated sections, which makes it more cost-effective.

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Types of Defence Components We Manufacture at Zeal 3D

Precision Military Components: Components used in the military and the defence industry must survive a variety of extreme conditions, such as heat, friction, salinity, and grit. Producing precision-machined parts for every division of the armed services is necessary to meet all pertinent military standards and regulations and to endure hostile environments.

Aircrafts Machined Parts: CNC machining is a good and highly reliable production technology for aircraft engineering purposes because of the exceptionally high level of accuracy required here. This technology can produce metal and plastic parts for aircraft devices with extremely tight tolerances, which enables it to provide industry-reliable solutions. Aircraft engineers can quickly create new prototypes for spare parts, test them, and make changes to them in real-time since CNC machines use instructions from 3D CAD models to fabricate parts.

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Weapon Mountings: Modern 3D engineering services like 3D printing and CNC machining can be utilized to construct weapon mounting systems that securely attach a weapon—typically a gun—onto a platform so that it can perform to its fullest potential.

Aerospace Couplers: By choosing an appropriate and suitable material based on its level of efficiency, aerospace couplers can be produced using CNC machining for aerospace engineering purposes. If you want to replicate or make an exact copy of an aeronautic coupler, a 3D scanning process must be done initially, followed by CNC machining.

Missile Components: From fuselage sections and wing ribs to jet engine casings, CNC machining centres are perfect for producing high precision missile components for the defence sector. By employing computer numerical control (CNC), manufacturers can replace hand-controlled machines, vertical millers, and lathes with a computerized automated system, enabling them to produce missile components with a high degree of precision. With as little as.0001 variance between parts, CNC machines turn computer-aided layout models into mass-produced components.

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3d printing for aerospace
3D Printing for Defence

Defence Industry

According to the Australian Trade and Investment Commission, the Australian Government will invest more than $200 billion over the next ten years to increase the capability and expertise of the Australian Defence Force. Due to the fact that investment will fuel expertise and innovation, Australia's defence sector is in a strong position to export cutting-edge goods, technologies, and services. Australian defence equipment manufacturers can increase their capacity in the manufacturing of goods and components supporting defence needs by leveraging significant defence investments and long-term commitments. This includes producing cutting-edge defence components like advanced materials, protective element tools, and advanced multifunctional fabrics in order to maintain a competitive advantage in the field of warfighting. This is primarily accomplished by contract manufacturing protective instruments, such as hard armour plates, soft insert technologies, and helmet structures, together with sophisticated ceramics, composites, and textiles.

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