“This is bigger than simply printing parts. We are reshaping the sUAS enterprise at the tactical level,” stated Colonel Travis McIntosh of the 101st Airborne Division. Those are his own words that hold the revolutionary potential of adding 3D printing to drone warfare a union which has the potential to re-shape warfare as we know it. With the world’s military forces fighting everywhere from supplies to quickly changing battlefield situations, additive manufacturing proves itself to be a solution with the potential to fill those needs head-on.
The idea is straightforward and powerful: allowing soldiers to produce drones and spare parts on the frontlines themselves. The technology not only lessens reliance on conventional supply chains but also improves readiness operations. As the U.S. Army Combat Capabilities Development Command (DEVCOM) describes, the integration of 3D printing into frontlines operations provides a single benefit. The technology enables quick production of vital equipment, such as drones, to tactical requirements on short notice. The Army’s field testing of small, ruggedized 3D printers shows the potential of additive manufacturing to cut weeks-long lead times for vital components down to hours.
A case in point is the activity by the 101st Airborne Division at the EagleWerx Applied Tactical Innovation Center. Troops have started producing small-unmanned aircraft systems (sUAS) that are rugged, flexible, and disposable. During Operation Lethal Eagle, the unit tested 100 unmanned aerial systems produced through 3D printing, demonstrating its capacity to prototype and deploy drones for a fraction of the cost of conventional systems. “One Soldier in particular that has experience with all of the previously fielded sUAS was surprised with its performance,” said Capt. Andrew Blomquist, citing the user feedback.
The advantages extend beyond expense. Additive manufacturing is flexible and customizable, allowing soldiers to modify drone designs for individual missions. The Hellhound S3, for instance, a turbojet-powered Cummings Aerospace kamikaze drone, is an example of versatility. Less than 25 pounds in weight, it delivers long-range strike against defended targets to Infantry Brigade Combat Teams. Sheila Cummings, Cummings Aerospace CEO, emphasized its efficiency “Speed matters, and quadcopters and prop-driven drones take too long to get downrange.”
Aside from individual drones, the strategic value of 3D printing is immense. The Department of Defense 2022 Additive Manufacturing Strategy states that taking advantage of this technology is critical in regards to guaranteeing logistical resiliency in areas of contention. Military force manufacture in decentralized capabilities can limit exposures to vulnerabilities associated with supply chain disruption and actions against logistics networks. The RAND Corporation again stresses the flexibility of additive manufacturing, further pointing out that it can give commanders solutions custom-suited to their requirements as the needs of the mission change.
But the application of 3D printing to warfighting operations has its issues. Maintaining the integrity of printed parts in the extreme conditions of the battlefield is a major issue. Propellers and camera mounts, as flight-critical components, have to withstand demanding performance requirements. The shipping logistical problem of transporting printing material such as filament and resins into the field also presents practical challenges. Cybersecurity is another key concern; electronic blueprints and 3D files can be exposed to enemy tampering.
In spite of these problems, the future of military 3D printing is bright. The worldwide market for military 3D printing, at $0.88 billion in 2021, will reach $7.5 billion by 2031. This rapid growth is due to increasing awareness of the technology’s potential to revolutionize defense manufacturing and logistics. For example, the Navy already has discovered that it can 3D print parts of a submarine body within four weeks with a savings of as much as 90%. In the same way, additive manufacturing is already utilized in the Air Force to manufacture titanium cockpit components in stealth fighters that are more resilient and resistant to corrosion.
Drone warfare promises to be especially promising. 3D printing facilitates rapid prototyping of novel shapes, including arrays of micro-drones that could be used to carry out reconnaissance or electronic warfare to jam the adversary radar. The Perdix swarm, deployed from fighter aircraft, is the most tangible demonstration of how metal 3D printing and AI-generated geometries would be capable of expanding the war envelope of drones. Additionally, the capability to create drones as attritable assets low-cost, expendable platforms holds significant tactical benefits. Drones are easily used for risky operations without the risk of losing costly equipment or endangering human lives.
As military forces continue to push the boundaries of 3D printing, its value to battlefield flexibility only becomes more apparent. From creating mission-dependent drones to supporting equipment of earlier generations, additive manufacturing provides an adaptive kit of tools to current conflict. Though reliability, training, and cyber issues are persistent, additional investment in materials and processes is more than adequate to overcome these obstacles.
Finally, last but not least, the matrimony between drone technology and 3D printing is an army planning revolution. By providing for on-demand manufacturing and curing the logistical exposures, this cutting-edge technology is capable of transforming the future of war. It’s not that much about the printing of spare parts, aptly put by Colonel McIntosh himself there’s a complete transformation of the tactical environment on the cards.
