DEEP DIVE: Ukraine’s decentralized 3D-printing war goods industry

BLUF: Volunteer initiatives across Ukraine use 3D printers to produce ammunition for the frontlines. This innovation allows the military to quickly obtain parts often lacking on the battlefield, such as drone munition carriers, mine casings, and military ammo boxes. 

As Yurii Sakhno walked into his Kyiv office, he was immediately enveloped in a sweet aroma — the scent of 'corn' plastic, a biodegradable material used to produce the dozens of objects he 3D prints weekly to help the frontlines in Ukraine.

This innovation allows the military to quickly get parts of ammunition often lacking on the battlefield. The civilians print the casings – and then the military adds the explosives.

"K2 drone munitions, 'prianyk' bomblets, and other 3D-printed items are now widely deployed. They significantly slow down the enemy's advance," Sakhno, who contributes to the volunteer-run Druk Army, said.  

Yevhen Volnov, the founder of that volunteer-run organization, told Counteroffensive.Pro that his team is allowing military engineers to scale ammunition production on the frontline rapidly. In 2024, the Druk Army team delivered 277 tons of 3D-printed products to the front, totaling 11 million units. 

"Among them, 2.724 million were shells. A large portion consists of tail fins and nose cones, which help repurpose old factory-made ammunition or stabilize improvised explosive devices (IEDs) made from plastic tubes," Volnov said.

Currently, the Druk Army has 11,000 printers, but Volnov is looking to purchase more. Yet, funding and power outages have slowed expansion. 

3D printing is powering Ukraine’s military supply chain

Ukraine’s Armed Forces submit requests for supplies to the Druk Army website. A registered user then produces and ships the needed supplies to the front line. Volunteers told Counteroffensive.Pro that some of the most common requests include containers for drone-dropped munitions, boxes to hold ammunition, electronic programming equipment, and mine casings.

“Once you’ve printed your first few kilograms of plastic, you’re no longer a newbie and can take on more complex orders,” Nataliia*, another volunteer at Druk Army, said. “I liked printing a large drone munition; I think it was for four kilograms.”

Another startup company, Zmiyar, uses 3D printers to create casing boxes for mines — wooden boxes that usually contain explosives. Victor Shapovalov, CEO and founder of Zmiyar, said Russia focuses on serial production while Ukraine relies on 3D printing technology. 

Russia uses serial production and makes all the parts much faster. But setting up serial production takes a lot of time — it requires cutting the right shape of needed materials on machines, making many test samples, and only then starting full production. Russia has been doing this for many years.

Ukraine, on the other hand, did not have such developed mass production processes. Now, because of the war, Ukraine has to act fast. The best option for this is decentralized 3D printing. It is more accessible and can be done quickly. In theory, anyone can buy a printer and make shells at home. 

“We also don’t use serial production because the molds for molding machines are very expensive — each one costs at least $5,000 or more,” Shapovalov said.

The strengths and weaknesses of different plastics in 3D printing

There are three types of plastics that can be used: 

When it comes to pricing, PLA is the most affordable, while ABS is the most expensive.

PLA – $8–$20 – 3Dplast

PETG – $12–$22 – Pro3D

ABS – $14–$24 – Plexiwire

3D printers can use different types of plastic. Sakhno said that 'corn' plastic — also known as Polylactic Acid (PLA) — is made from plant-based raw materials such as corn starch and sugarcane and is widely used to produce materials used in everyday life, such as children's toys. However, he added, it is less durable and not tolerable to high temperatures. 

"At 60 degrees Celsius, it becomes like plasticine. It might even melt if you leave it in the sun during summer,” Sakhno said. “It's quite a peculiar material.”

Sakhno is now also using PETG (Polyethylene Terephthalate Glycol-Modified), an advanced version of PET (Polyethylene Terephthalate) that is often used for plastic bottles. Sakhno said glycol is added to increase the object's flexibility and impact resistance. Yet, this type of plastic is more sensitive to fine threads during printing.

Another type of plastic used for 3D printing is ABS (Acrylonitrile Butadiene Styrene). While it is known for being strong and impact-resistant, it also releases a strong odor during printing. Manufacturers said it is mainly used for technical parts and casings.

Shapovalov, CEO of Zmiyar, which produces casing boxes for mines, said PLA plastic, for example, is unsuitable for these products. 

"PETG might be sufficient," Shapovalov explained."Printing with ABS is also a great option." Yet, he added that PETG barely shrinks — meaning the print stays truthful to the size of the design — while ABS can shrink during production. 

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Chinese export restrictions and the rising costs of 3D printing 

The 3D printing industry in Ukraine relies heavily on Chinese components to build printers. These include charging boards, thermal sensors, extruders and hotends. Yet, as Beijing tightens export restrictions, manufacturers face rising challenges in affording quality materials. 

“You can wish for many things, but charging boards aren’t produced in Kyiv or Lviv — they’re made in China. The key is using our limited resources efficiently,” Volnov said.

Earlier this month, The Wall Street Journal reported that Chinese suppliers had begun limiting the export of key drone components to the U.S. and Europe. In December 2024, China banned the export of materials to the U.S. that are crucial for semiconductor manufacturing, which is an essential part of producing 3D printer components.

Before Russia’s full-scale invasion, a Creality Ender-3 V3 SE printer cost around 8,000 UAH ($190 USD). Now, the price has risen to 15,000 UAH ($355 USD). 

Yet, Nataliia said that several 3D printer materials, such as filament (plastic), can be found in Ukraine but for a higher price. And the quality might be lower. For example, it may have an uneven diameter, a brittle surface, or absorbs too much moisture during use. If supplies from China were to stop, Nataliia said, they would look for alternatives within Ukraine.

“There are domestic filaments like 3Dplast, but we use Chinese filaments because 3Dplast has many issues. Many people have complained; some even had their printers break. If you have a good printer, you don’t want to risk it,” Nataliia said.

Ukrainian manufacturers have begun using European, American, and Taiwanese components to reduce dependence on Chinese suppliers. In addition, Shapovalov said that many needed components, which have already been imported into Ukraine from China, are being stored in warehouses and will be used soon.  

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The cost, time, and impact of 3D-printed military supplies 

The time and cost of 3D prints vary according to the type of printer used, the object, and the amount of plastic needed.

“Everything depends on the item you’re printing. Some small, thin technical parts take a long time because they require very fine layers, even though they consume only 50–100 grams of plastic,” Nataliia said. She added that a single stabilizer — a ‘tail fin’ — for a handheld shaped-charge grenade can take about six hours.

Druk Army volunteers work with various 3D printer models, including the Bambu Lab P1S and Bambu Lab A1 Mini, which cost around $250 — among the most affordable on the market. 

“If you drop one of these grenades from a Mavic drone onto a tank, you can damage it. A single tail fin costs just 50 UAH ($1.20 USD), and the grenades we have in stock. So, with a Mavic drone and 50 UAH ($1.20 USD), you can destroy an expensive multi-million dollar tank,” Volnov said.

A single 3D printer can consume about 0.5 kilograms of plastic daily — totaling 15 kilograms a month. A filament costs 300 UAH — $7 USD — per kilogram, which means its cost can reach about 4,500 UAH ($107 USD) per month per printer. 

Sakhno’s 11,000 printers cost him about 50,000 UAH ($1,187 USD) monthly. To support the funding, he uses money from his pocket, collects donations, and receives financial support from the Druk Army.

In addition to the high costs, 3D printers require weekly supervision and maintenance. Sakhno said he has to repair his printers a few times a week. Yet, as he has learned how to fix them, he does not have the additional cost of hiring a specialist. 

“For these printers, it’s crucial to keep the environment dry because the plastic absorbs moisture, which affects print quality,” Sakhno explained. 

The limitations and risks of implementing 3D printers on the frontline 

Despite 3D printing having become a key part of Ukraine's expansion of local ammunition production, it still does not account for the total output of the item. 

Ammunition is a complex system that includes a body, a striking element, a stabilizer, and many other parts, not all of which can be 3D-printed, a former advisor to the Minister of Strategic Industries, Ihor Fedirko, told Counteroffensive.Pro.

"In my opinion, non-standardized, uncertified ammunition is too risky for the Ukrainian military, as it endangers soldiers," Fedirko said. Yet, he added that the Druk Army is an “incredible ally.”

And, in certain field conditions with an urgent need, soldiers may use printed shells, adding explosive components and assembling the ammunition themselves, Fedirko added. He said that Ukrainian military personnel undergo foreign training in advanced metalworking, 3D printing, stamping, and new welding technologies when needed.

"They return to Ukraine as trained specialists. And, of course, equipment for our defense industry is being ordered specifically for them," Fedirko said.

In addition, Shapovalov noted that the government supports filament manufacturers by providing discounts and special programs.

Yet, Druk Army founder Volnov argued that the government does not support such initiatives. 

“State management is the most inefficient system ever created,” Volnov said.

*Certain details are omitted for security reasons.

Correction: The Counteroffensive made an error in the original version of the post.

We originally misstated the number of printers that the Druk Army has. The correct figure is 11,000 printers.

We apologize for the error.

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