3D printed bullets? Ares and Aurora Labs partner to explore the art of the possible

Ares Armaments Australia has entered into a memorandum of understanding (MoU) with Aurora Labs (A3D) to explore the opportunities for 3D printed components in small arms ammunition. The agreement is “expected to advance production of lighter, stronger, more consistent and cost-effective components,” the November 17th press release explains. 

Ares already produces a range of precision ammunition for the small arms market, including the Rooster C-UAS round announced at DSEI. Rooster can be fired from a 7.62 mm rifle and fragments before impact to take down small drones with reduced collateral damage. 

Working with Aurora, the two companies will “collaborate to accelerate R&D into the use of exotic metals in small-arms ammunition and armaments. Initial focus will be on how alloys and A3D’s advanced metal processing capabilities can be used to produce lighter, stronger, more consistent and cost-effective components that improve performance,” the press release states. All whilst adhering to existing regulatory standards, of course. 

The initial project is expected to focus on select components, and both companies have already shared some information with prototyping and testing expected in 2026. Once testing is complete, the companies will be engaging with the Ares customer network, which includes law enforcement agencies in Australia. 

• DSEI UK 2025: Ares launches Rooster C-UAS round in 7.62 mm 
• DSEI 2025: ARES Armaments and Torchlight partner for ammo taggant – Calibre Defence
• Defence in brief: ARES Armaments and Aimpoint partner for Australian growth

The MoU also aims to build awareness of Australia’s advanced manufacturing capabilities amongst defence and government stakeholders. Australia is working hard to build its domestic defence industry and increase its ability to meet its needs without imports. This is reflected in developments across the spectrum of defence, from large collaborative combat aircraft like the MQ-28 Ghost Bat, through to armoured vehicles including the AS21 Redback, and small arms ammunition. 

Calibre comment: 3D printed bullets?

A cottage industry of innovation and adaptation has sprung up around the war in Ukraine, and some of it is more organised than other parts. Videos have emerged of Russian and Ukrainian workshops developing new ammunition for their assault rifles. Initially, they would pull the 5.45 mm round out from the cartridge and replace it with steel ball bearings in a shrink-wrapped tube. However, according to the YouTube channel The Armourer’s Bench, it seems that the tubing was fouling the barrels. However, the Assault Detachment of Russia’s 33rd Regiment, 20th Guards Motor Rifle Division, has developed a 3D printed sabot that holds four BBs. Another Russian group developed a similar technology,  which went through several iterations based on user feedback. As noted by The Armourer’s Bench, 3D printing allows thousands of sabots for the BBs to be printed relatively quickly, leaving only the loading of the rounds as the bottleneck. It is not yet clear what Ares and Aurora are planning to 3D print, we’re waiting for further details, but this example from Ukraine helps to illustrate some of the ways that this technology is being used in small arms production. 

By Sam Cranny-Evans, published on November 17th, 2025. The lead image shows the Rooster ammunition from Ares Armament Australia.