The recent conflicts across the world have been a wake-up call for all the big military powers about not only the effectiveness of drones but also the eventuality that military drones are the new normal. Therefore the US Army has decided to 3D print drone swarms on priority for combat training. And it has now created realistic training scenarios for soldiers facing emerging battlefield threats.
The military has initiated a production program that manufactures small aerial drones specifically designed to simulate enemy unmanned aerial systems during combat exercises.
This initiative comes as military leaders observe the increasing use of drone swarms in global conflicts, particularly in Ukraine where forces are utilising 3D printing to rapidly deploy unmanned systems, and in Myanmar where rebel groups have transformed their capabilities through similar manufacturing techniques. The Army aims to produce these training drones at a fraction of the cost of combat-ready systems while maintaining the realism needed for effective training.
Army to 3D Print Drone Swarms
The Army’s drone manufacturing process currently operates across two specialised facilities. Rock Island Arsenal in Illinois handles the 3D printing of drone airframes and components, after which the partially completed units are shipped to Tobyhanna Army Depot in Pennsylvania for electronics integration and finalisation.
Production remains in its early stages, with current output reaching approximately 10 Group 1 drones weekly. These lightweight unmanned systems, weighing less than 20 pounds (9 kg), serve as realistic training aids without the expensive cameras and advanced systems found in combat versions. Army Futures Command head Gen. James Rainey emphasised this point, stating, “We need to do it at a price point that is ridiculously low: We don’t need the Gucci cameras and everything else.”
Scaling Production Capabilities
The Army is currently evaluating whether to dramatically expand its drone manufacturing capacity. According to Lt. Gen. Christopher Mohan, acting commanding general of Army Material Command (AMC), the service expects to make this decision within months after proving the initial concept’s viability.
If approved, the Army could transition from 3D printing to injection moulding techniques, where components are formed by pressing material over predetermined moulds. This manufacturing shift could potentially increase production capacity to approximately 10,000 drones monthly, providing ample training resources for soldiers preparing at the National Training Center and Joint Readiness Training Center.
The manufacturing initiative began with the 101st Airborne Division, which sought ways to leverage existing advanced manufacturing capabilities within the military. Working with Army Material Command, they developed a drone production “sprint” program that has demonstrated the feasibility of in-house drone manufacturing for training purposes.
Expanding Advanced Manufacturing Applications
Beyond training drones, the Army is exploring how 3D printing technology can support a wider range of military equipment. A second sprint program focuses on creating digital twins of critical military assets including UH-60 Black Hawk helicopters, AH-64 Apache attack helicopters, and M113 personnel carriers.
These digital models will help the Army identify which components can be effectively produced through advanced manufacturing techniques.
“We’ll basically digitally map that entire vehicle and then apply advanced manufacturing and say, ‘Okay, the following parts can be produced with advanced manufacturing’.”
– Lt. Gen. Christopher Mohan, acting commanding general of Army Material Command (AMC)
The approach reflects a broader military shift toward distributed manufacturing capabilities that can reduce dependency on fragile supply chains. By developing the capacity to produce components and systems locally, the Army aims to increase readiness while reducing costs and logistical burdens associated with traditional procurement channels.
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