UK defense supplier NP Aerospace has successfully produced a 110 kg suspension and differential carrier assembly for the Mastiff heavy armored patrol vehicle using Wire Arc Additive Manufacturing (WAAM). The component was manufactured by the UK’s Digital Manufacturing Centre (DMC) using DED-arc additive technology, with metal wire deposited layer by layer followed by precision machining. Traditional casting or forging processes for such large structural parts take 6 to 9 months to deliver, while the 3D printing approach dramatically shortens this to just weeks. This project demonstrates the significant potential of additive manufacturing in defense supply chains for rapid response, reduced spare part costs, and improved equipment availability.