How Xometry helped AADS deliver a next-generation military ambulance at speed

Vehicle specialists AADS needed high-volume steel fabrication for a new Jeep J8 ambulance conversion, fast. Xometry’s manufacturing network helped deliver critical components while simplifying the supply chain.

Developing a new military vehicle variant is rarely straightforward – especially when key structures need to be redesigned and delivered against a tight production timeline. 

That was the challenge facing Gibraltar-based vehicle specialist AADS as it developed a new militarised ambulance conversion for the latest Jeep J8 Wrangler.  

To meet the programme’s tight schedule, the company turned to on-demand manufacturing platform Xometry, tapping into its vetted network of certified suppliers to deliver structural components without increasing procurement overhead. 

Mark Jensen, Head of Technical and Production at AADS, said, “Partnering with Xometry made perfect sense for us. Their model freed us from supply chain worries so we could focus on our core work. Knowing they had all the necessary fabrication and manufacturing links meant we didn’t have to find suppliers ourselves – that was key.”  

Military ambulance conversion: Redesigning the Jeep J8 under tight deadlines

AADS is best known for its Jeep J8 conversion programme, transforming series-production vehicles into bespoke troop carriers, ambulances, patrol vehicles and command vehicles for military and government customers, including the US Department of Defence. 

This particular project was to convert the new Jeep J8 Wrangler model into a militarised ambulance. It was the first time the conversion had been applied to the updated platform, and meant the body extension, fibreglass roof and internal ambulance pod all had to be redesigned from scratch. 

With a demanding schedule – roughly twelve months from order to delivery, with vehicles needed for logistics within eight – the team needed a manufacturing partner capable of matching its speed. 

From rapid prototyping to high-volume steel fabrication

AADS first discovered Xometry while searching for rapid prototyping support. They liked the instant quoting engine – dragging and dropping a CAD file returns immediate pricing and lead-time feedback – which lets engineers iterate on designs, materials and processes in real time rather than waiting days for a manual quote.  

The relationship quickly expanded from prototyping into full metal fabrication, tapping Xometry’s high-volume steel welding and sheet fabrication capability to meet the series-production quotas the ambulance programme demanded.

For the militarised J8 fleet, Xometry manufactured two structurally critical steel components: a 550mm steel body extension providing the space needed for the ambulance conversion, and a tubular steel framework, finished in white powder-coat. This added rigidity to the body, supporting the patient attendant seat and helping carry the fibreglass roof.  

Because both parts were structural elements of the build, Xometry supplied an initial sample for verification against AADS’s drawings and tolerances before series production began, giving the team confidence in accuracy ahead of volume manufacture. 

Just as valuable as the fabrication itself was what sat around it. Xometry’s network of vetted suppliers and its handling of logistics meant AADS didn’t have to source or manage multiple vendors of its own. This meant its engineers could concentrate on design and development while production ran in parallel. 

Mark Jensen, Head of Technical and Production at AADS, said, “The Xometry website was fantastic; just dragging and dropping a CAD model gave us instant pricing feedback. Being able to instantly change materials or manufacturing processes was incredibly useful.” 

Why aerospace and defence companies are turning to Xometry

The AADS project highlights how Xometry supports aerospace and defence customers facing demanding production schedules and complex supply chain requirements.  

Through a network of more than 5,000 vetted suppliers, the company provides access to a wide range of manufacturing services, including CNC machining, metal and additive manufacturing, sheet fabrication and injection moulding. 

These capabilities are complemented by more than 50 post-processing options including MIL-spec finishes, anodising and passivation, all managed through a single platform. 

For defence and aerospace programmes specifically, that translates into:  

• NDAs provided as standard with full data and CAD security;  

• End-to-end material and process traceability, with CMM inspection and First Article Inspection (FAI) reports to guarantee compliance;  

• Access to over 200 industrial-grade materials, from titanium and Inconel to high-temperature resins and engineering plastics;  

• Instant design-for-manufacturing (DFM) feedback to catch production risks before they become costly redesigns. 

For programmes facing legacy obsolescence or surge production demands, framework agreements are available to lock in long-term pricing stability and supply continuity.  

For AADS, the combination of manufacturing capacity, supplier management and scalable production support helped them turn around a complete structural redesign inside an eight-month window. 

For more information, visit Xometry’s aerospace and defence page at xometry.uk