The US Army is intensifying its efforts to accelerate the production of 3D-printed drones designed to mimic the capabilities and behaviors of enemy systems. This initiative is part of a broader program focused on quickly developing low-cost target drones for military training exercises, as outlined by Gen. James Rainey, head of Army Futures Command. He emphasized the pressing need to simulate unmanned aerial system (UAS) threats, particularly as forces prepare platoons to respond to emerging threats like drone swarms.
“There is a critical requirement for us to achieve this at a remarkably low cost. We don’t need the premium features like the high-end cameras,” said Rainey, highlighting the need for affordable production methods in military training systems.
Currently, the army produces around 10 Group 1 drones weekly, each weighing under 20 pounds and capable of reaching speeds of up to 100 knots. However, plans are being put in place to increase this output significantly to an ambitious target of 10,000 drones per month, which is expected to enhance training for modern combat scenarios. Army Materiel Command’s acting commanding general, Christopher Mohan, mentioned that while it may take months to finalize decisions on production ramp-up, there is confidence in the army’s ability to scale production, particularly for larger drone systems.
The incorporation of 3D printing technology is a game-changer for the army, enabling the production of essential components—from drones to various equipment parts—at unprecedented speed and affordability. This approach is said to significantly shorten production timelines, facilitating rapid deployment and enhancing operational efficiency.
Reflecting the military’s shift toward advanced manufacturing, the US Air Force showcased in May 2024 its capability to design, build, and deploy 3D-printed UAS in less than 24 hours, marking a significant advancement in military readiness. The army has also successfully tested a loitering munition that was produced using additive manufacturing, demonstrating its effectiveness in operational scenarios.
Beyond the realm of drones, the military is expanding the application of 3D printing technology to include constructing facilities and quickly repairing vehicles, which addresses various logistical challenges. Dave Morrow, director of military programs for the Army Corps of Engineers, pointed out that additive construction has the potential to reduce costs, labor, and logistical hurdles, while also paving the way for new and innovative applications, including unconventional countermeasures. This strategic pivot not only reflects a modernization of military capabilities but also a commitment to enhancing the efficiency and effectiveness of US armed forces in contemporary warfare.
