● Covered by 1 source · 1 reportMedium impact1 neutral
US Navy 3D Prints Drones and 1,000+ Parts Aboard USS Essex During RIMPAC Transit
Key points
- A containerized 3D printing factory operated on the USS Essex.
- Produced 12 Squall FPV drones and over 1,000 parts, including Apache helicopter spares.
- Manufacturing occurred during rough seas with 12-foot waves.
- Drones were used as adversary aircraft in a counter-UAS exercise.
On-Demand Manufacturing at Sea
During a two-week transit to RIMPAC 2026, the US Navy utilized Firestorm Labs' xCell expeditionary manufacturing platform aboard the USS Essex. This containerized factory successfully 3D printed a dozen flight-ready Squall FPV drones and over 1,000 other parts, including critical spares for Apache helicopters.
The xCell platform, housed in two expandable 20-foot ISO containers, includes industrial HP Multi Jet Fusion polymer printers and semi-automated assembly stations. This marks the first maritime deployment of the system, demonstrating its capability to operate effectively in challenging conditions, including rough seas and 12-foot waves.
Combat Drones and Critical Spares Produced
Among the items produced were 12 Squall FPV drones, which have a range of up to 20 miles, a flight time of up to 42 minutes, and a top speed of 80 mph. These drones were subsequently used as adversary aircraft in a counter-UAS exercise upon the USS Essex's arrival at RIMPAC.
Beyond drones, the system fabricated essential spare parts such as Apache helicopter rotor droop-stops, designed to prevent rotor damage, and a custom vacuum-hose coupling for life preserver testing. The more than 1,000 3D-printed parts also included various crew-requested items like electrical fitting covers and Starlink mounting brackets.
Impact on Naval Logistics
This successful deployment highlights the potential for expeditionary manufacturing to transform naval logistics. By enabling on-demand production of parts and equipment at sea, the technology can reduce the need for traditional resupply chains, thereby cutting fuel consumption, aircraft hours, and personnel requirements.
The ability to produce critical components rapidly on-site means that repairs that previously required days or weeks of waiting for resupply can now be completed in hours, directly impacting operational readiness and efficiency for naval forces.
✨ This summary was generated by AI from the outlets' reporting listed below. It is not independently verified and may contain errors — check the original sources. How BrevFeed works →
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Reporting from
The US Navy successfully 3D printed a dozen combat-ready drones and over 1,000 spare parts, including critical Apache helicopter components, aboard the USS Essex during a two-week transit to RIMPAC 2026. This demonstration, using Firestorm Labs' xCell expeditionary manufacturing platform, proves the viability of on-demand additive manufacturing at sea, even in rough conditions. The ability to produce parts and drones on-site reduces reliance on traditional supply chains, potentially cutting resupply times and operational costs for naval operations.