Photo by LCpl Alpha Hernandez / USMC (Photo ID 6969813)

In 2025, a new wave of technologies and approaches is reshaping how military organizations around the world maintain their fleets, bases, and infrastructure. These innovations go beyond cost savings to include survivability, autonomy, and operational superiority. Simply stated, today’s battlefield is defined by the capacity to keep complex, mission-critical assets in constant readiness.

What follows is a journey through the eight most impactful trends redefining defence maintenance, backed by real examples and the latest policy shifts. Together, they illustrate how maintenance has evolved from a supporting activity to a decisive factor in combat power.

Figure 1. Breakdown of the U.S. defence budget (2025). Nearly 40% is allocated to operations and maintenance, underscoring its central role in military readiness.

AI Predictive and Prescriptive Maintenance

The shift from reactive maintenance to predictive approaches is now a reality across many military branches. Artificial Intelligence (AI) and machine learning (ML) are embedded into modern maintenance ecosystems, enabling the transition from predicting failures to prescribing the best course of action.

A case in point is the USS Fitzgerald, a U.S. Navy destroyer equipped with Enterprise Remote Monitoring v4 (ERM). This system analyses over 10,000 sensor signals per second, offering a real-time health profile of machinery onboard. Instead of scheduling maintenance based on calendar intervals, the system advises commanders exactly when and where intervention is needed.

The payoff is enormous: reduced downtime, optimized spare part usage, and increased combat readiness. A system failure at sea can immobilize a vessel for weeks, but predictive tools allow maintenance teams to act proactively during planned stops.
Innovation is not limited to ships. The U.S. Air Force is testing AI-powered algorithms for engine health monitoring on fighter jets, while NATO allies are investing in predictive vehicle maintenance to extend the service life of armoured fleets deployed in Eastern Europe.

AI-driven maintenance is not a niche experiment but a global movement reshaping readiness doctrines. NATO allies are increasingly pooling resources to build shared AI platforms that harmonize maintenance data across different fleets, making multinational operations smoother. In the United Kingdom, the Royal Air Force has launched pilot projects where predictive analytics monitor Rolls-Royce engines on Typhoon fighters, cutting unscheduled downtime by double digits. In Asia-Pacific, Japan’s Self-Defence Forces are integrating AI into naval fleet diagnostics, while South Korea is experimenting with predictive maintenance for its K2 Black Panther tanks.

Still, certain challenges remain. AI systems demand clean, labelled data, often scarce in legacy platforms. Algorithms must be explainable to gain the trust of military decision-makers. And cybersecurity is paramount: a manipulated dataset could trigger false recommendations with severe consequences.

Figure 2. AI-enhanced military maintenance cycle. Predictive and prescriptive analytics connect maintainers, repair shops, warehouses, and supply chains to improve availability, efficiency, and capacity while reducing shotgun maintenance

Right-to-Repair: Empowering the Frontline

Running parallel to AI is a quieter but equally revolutionary development: the right-to-repair movement. For decades, military units were dependent on original equipment manufacturers (OEMs), often waiting weeks for authorized technicians or proprietary parts. In combat, that dependency is a liability.

In May 2025, the U.S. Department of Defense announced the “right to repair” provisions will become standard in Army contracts. Soldiers will gain access to manuals, diagnostic tools, and digital files needed to fix equipment themselves—even fabricating replacement parts when necessary.

This development is critical in theatres where logistics convoys are vulnerable to attack. A battalion stranded by a minor equipment fault can jeopardize an entire mission. If they have the right to repair, troops can patch and restore vehicles within hours instead of waiting for OEM support that might never arrive.

Some compelling applications are emerging in aviation and naval domains. U.S. Air Force depots are exploring right-to-repair concepts for F-35 subsystems, allowing local teams to bypass long OEM approval times. Navies are experimenting with giving submariners autonomy to service critical life-support systems at sea.

As these examples suggest, when operators who may be weeks away from supply hubs are empowered, even highly complex platforms can sustain themselves independently.

Yet the policy has tensions. OEMs are reluctant to release intellectual property, citing lost revenue and safety risks if repairs are improperly executed. The success of right-to-repair will depend on balancing sovereignty, safety, and IP rights. NATO nations are already discussing harmonization to ensure interoperability in joint operations.

Figure 3. Armed forces personnel exploring desktop 3D printers, demonstrating on-site fabrication of spare parts for greater agility and resilience. / Photo by Molly Rhine / U.S. Navy via DVIDS (Photo ID 5283818)

Additive Manufacturing and the Mobile Factory

Closely linked to the right-to-repair is the rise of additive manufacturing, better known as 3D printing. Once experimental, additive manufacturing has matured to the point of battlefield deployment. Programs such as Fleetwerx have developed mobile fabrication labs capable of producing spare parts in forward bases.

Whether made of metal alloys, ceramics, or composites, these parts reduce dependency on vulnerable supply lines. Imagine a combat vehicle disabled by a broken valve. Instead of waiting days for delivery, technicians can 3D-print the component within hours, often at reduced weight and optimized geometry.

The British Army has trialled containerized additive manufacturing units in deployed environments, producing small arms parts and UAV components. The U.S. Marine Corps has tested 3D-printed impellers for water purification systems, while the Australian Defence Force explored printing drone airframes during Pacific exercises.

Importantly for high-value platforms, additive manufacturing is moving beyond prototypes into certified airworthy parts. In 2025, the U.S. Air Force approved the first flight of an F-22 Raptor equipped with a 3D-printed titanium cockpit component. Naval forces are experimenting with printing pump impellers and valve housings directly onboard carriers. Submarine maintenance has benefitted as well: the Australian Navy has tested polymer 3D-printed gaskets able to withstand deep-sea pressures.

The real challenge is certification. Defence organizations require rigorous validation before deploying a printed part in mission-critical equipment. To address this, NATO is working on a joint certification framework for additive manufacturing. The vision is clear: every forward base could soon become a miniature factory, where supply chains are virtualized and resilience maximized.

Taken together, these first three trends highlight a decisive shift: maintenance is no longer confined to depots or long supply chains, but is moving directly into the hands of operators and frontline units. AI-guided troubleshooting, the ability to repair equipment without waiting for authorization, and the agility of additive manufacturing are transforming downtime into uptime and dependence into autonomy. Yet this is only part of the story. To truly harness these tactical gains at scale, armed forces are now embracing broader enablers — from digital twins and robotics to connected logistics and performance-based frameworks. These will be the focus of the next part of this article.

Text: Prof. Diego Galar