Innovations in Unmanned Aerial Systems: 3D-Printed Airframes at the 1st Cavalry Division
Introduction to Advanced Manufacturing in Military Training
The 1st Cavalry Division has established a groundbreaking laboratory dedicated to the development of 3D-printed airframes designed to support first-person view (FPV) drone operations. This initiative aims to enhance the training capabilities for small unmanned aerial system (sUAS) operators, aligning with recent directives from the Pentagon to incorporate sUAS technology into military exercises.
Rapid Production of UAS Components
Soldiers within the division can produce a complete unmanned aircraft system frame in just seven hours, utilizing advanced carbon-fiber-nylon filament. Once the airframe is printed, the integration of essential components such as batteries and sensors requires an additional 30 minutes. This streamlined approach significantly accelerates the deployment of operational capabilities.
Addressing Equipment Gaps
Chief Warrant Officer Rob Gatta, the officer overseeing the 1st Cavalry Concepts and Capabilities Laboratory (1-C3 Lab), emphasized a previously critical shortfall in equipment availability for soldiers. Prior to this initiative, no operational unmanned aerial systems were issued. The existing Short Range Reconnaissance (SRR) and Medium Range Reconnaissance (MRR) programs had not yet been made available to the 1st Air Cavalry Brigade. The alternative—acquiring an expensive UAS from the Defense Innovation Unit’s Blue UAS List—often led to reliance on advanced, costly systems that were not feasible for regular training needs.
Technological Advantages of Improved Printing Techniques
The laboratory’s initial attempts at producing airframes utilized Prusa and Bambu printers; however, those models lacked the necessary tensile strength for effective use as airframes. The transition to Pantheon printers, which leverage a carbon-fiber-nylon composite, has enabled the development of airframes with tensile properties comparable to aluminum. This advancement not only enhances structural integrity but also ensures the durability required for rigorous military applications.
Future Implications
The integration of 3D-printed airframes represents a significant leap forward in enhancing the operational readiness and training effectiveness of UAS operators within the military. By advocating for rapid prototyping and manufacturing techniques, the 1st Cavalry Division is setting a precedent for how military units can adapt and evolve in response to both technological advancements and operational requirements. This initiative showcases the potential for enhanced agility and responsiveness in military operations, potentially influencing future policies related to equipment modernization and training methodologies.
