3D-printed drones built on a US Navy ship for the first time, potentially opening a whole new world of possibilities for future warfare

Date:
Mon, 10 Aug 2026 22:40:00 +0000

Description:
Firestorm Labs manufactured 12 drones aboard USS Essex using a containerized 3D-printing factory during its voyage toward RIMPAC 2026.

FULL STORY ======================================================================Copy link Facebook X Whatsapp Reddit Pinterest Flipboard Threads Email Share this article 0 Join the conversation Follow us Add us as a preferred source on Google Newsletter Subscribe to our newsletter Firestorm Labs printed 12
drones aboard USS Essex during a Pacific voyage More than 1,000 drone components were manufactured directly aboard the warship The Navy tested
drone production while waves reached 12 feet Firestorm Labs has produced 3D-printed drones aboard a US Navy ship at sea, testing manufacturing without conventional shore-based logistics support systems.

The company manufactured more than 1,000 components and assembled 12 Squall first-person-view drones aboard USS Essex during its voyage toward Hawaii waters. The drones were subsequently flown as opposing aircraft during a counter-drone exercise conducted during the Rim of the Pacific, or RIMPAC, 2026. Latest Videos From TechRadar Watch full video here: Manufacturing
drones at sea Firestorm Labs used its xCell containerized microfactory to manufacture drone components and additional parts while the amphibious
assault ship remained underway.

The system functions as a compact production facility designed for Navy vessels, allowing crews to manufacture unmanned aircraft and selected replacement components. You may like US Navy plans for 'Air Wing of the Future' with next-generation, pilotless carrier-based 1,150-mile-range drones to fly alongside manned aircraft The US Navy used a swarm of drone boats to seize $81 million worth of cocaine in the Caribbean UK tests robot boat that can fly its own wired drone even in 14ft waves and stay at sea for weeks

During the trial, service members assembled drones while waves reached 12 feet, providing a demanding environment for onboard manufacturing operations.

Personnel also printed mechanical test components used to assess the effectiveness and performance of the equipment during production aboard the vessel. Are you a pro? Subscribe to our newsletter Sign up to the TechRadar Pro newsletter to get all the top news, opinion, features and guidance your business needs to succeed! Contact me with news and offers from other Future brands Receive email from us on behalf of our trusted partners or sponsors By submitting your information you agree to the Terms & Conditions and Privacy Policy and are aged 16 or over.

The same equipment was used to fabricate military repair parts required by
USS Essex personnel during the ships Pacific deployment.

Every part xCell printed on deck is one that doesnt need to be flown or shipped across contested waters cutting the fuel, aircraft hours, and personnel it takes to keep a ship operational, Firestorm Labs said via LinkedIn .

Repairs that once meant days or weeks waiting on a resupply run can now
happen in hours, on station. What to read next US will build Ukraines sea drones including the one that shoots down jets Anonymous Wild Hornets spokesperson calls drone swarms 'a fun legend and a scam mechanism' How a
tiny Hawaii startup is rewriting the rules of naval shipbuilding with 3D printers and 100% recyclable materials

Under the companys description, repairs requiring conventional supply
missions could instead be completed within hours when suitable production capability remains available.

The trial also gives Navy personnel experience operating a manufacturing system while managing shipboard conditions, equipment requirements, and production tasks simultaneously. A wider move toward containerized military capabilities The experiment comes as the Navy develops modular capabilities transported inside containers and deployed where conventional infrastructure remains limited during operations.

Chief of Naval Operations Adm. Daryl Caudle announced a containerized capability campaign plan in March during the McAleese Defense Programs conference.

His plan calls for transportable containers carrying capabilities such as drones and weapons to be deployed across different operational regions.

The Pentagon has separately pursued containerized munitions, with framework agreements announced in May involving Anduril, CoAspire, Leidos, and Zone 5.

Those agreements cover more than 10,000 containerized missiles scheduled for acquisition over three years beginning in 2027 under the program.

The Navys onboard drone production test combines this containerized approach with additive manufacturing conducted directly from an operating warship.

For crews operating far from established bases, such production could provide another method for obtaining selected drones and replacement components when needed.

However, the trial does not establish how reliably the system can sustain production during prolonged operations or under more demanding combat conditions.

Its practical value will depend on whether the equipment can consistently produce dependable aircraft and parts at useful rates during extended deployments.

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