The U.S. Army’s Transition to a Modern Drone Manufacturing Network

Enhancing Drone Production Capabilities

At Rock Island Arsenal, Illinois, the U.S. Army is embarking on a significant modernization effort aimed at transforming its aging industrial base into a cutting-edge network for drone manufacturing. The Army, however, faces substantial obstacles as it transitions from limited-scale prototyping to extensive production.

Lt. Gen. Christopher Mohan, acting head of Materiel Command, remarked on the complexity involved: “Our capabilities in traditional manufacturing are robust, but Unmanned Aerial Systems (UAS) require a different approach.” The Army demonstrates competence in producing wiring harnesses and some microelectronics, but it lacks critical capabilities like brushless motors, necessitating investment in new machinery.

Lessons from the Ukraine Conflict

The urgency of this technological upgrade is underscored by recent observations from the Ukraine conflict, where affordable drones and loitering munitions have dramatically altered the battlefield dynamics, rendering conventional forces vulnerable. Both Ukrainian and Russian forces have ramped up drone production, exposing a critical gap in the U.S. military’s manufacturing capabilities.

In contrast, the U.S. defense establishment has relied heavily on commercial contractors and limited pilot production runs, illustrating the pressing need for a robust domestic supply chain capable of quickly producing large quantities of drones.

The SkyFoundry Initiative

To address these challenges, the Army has launched the SkyFoundry project—a groundbreaking effort aimed at converting traditional depots and arsenals into a network of distributed drone manufacturing facilities. The initiative seeks to achieve the ambitious goal of producing 10,000 small, expendable drones monthly, similar to those being deployed in Ukraine.

Col. Eloy Martinez of Rock Island Arsenal emphasized, “Unlike in Ukraine, we do not face an existential threat, allowing us more time to strategize our production capabilities.” However, he acknowledged the bureaucratic hurdles that hinder progress: “The question remains: how do we break these barriers to expedite our capabilities?”

Imperative Action Required

Brig. Gen. Beth Behn, heading the Army Tank-Automotive and Armaments Command, affirmed the importance of immediate action for adapting to the rapidly evolving drone threat. Having spent considerable time with the Security Assistance Group in Ukraine, Behn observed firsthand the urgent need for transformation within Army frameworks. She highlighted a newfound recognition of the drone threat, stating, “We have implemented drone operator training and initiated production, quickly integrating capabilities into our combat formations.”

Advancements in Manufacturing Technology

Rock Island Arsenal is taking significant steps in employing advanced manufacturing techniques, including 3D printing. Substantial investments have been made in a state-of-the-art facility that accommodates various printers capable of producing diverse drone components.

• Current Capabilities:
  • Production of drone frames and bodies using additive manufacturing
  • Anticipated integration of advanced 3D-printing technology from Impossible Objects, projected to yield 120,000 drone bodies annually

Once operational, this technology could enable production rates of 60 drones per hour at costs below $100 each, facilitating the development of expendable systems for combat operations.

Collaborative Efforts Across Army Depots

Collaboration among various Army installations is central to optimizing production. Tobyhanna Army Depot will focus on wiring harnesses, microelectronics, and brushless motors, while Red River Army Depot in Texas is slated to handle battery manufacturing and final assembly. As Lt. Gen. Mohan noted, “SkyFoundry represents not just a single location but a comprehensive concept for networked manufacturing, allowing specialization while maintaining interconnectivity through a centralized data repository.”

The Vision for UAS Innovation

The Bluegrass Army Depot in Kentucky is poised to serve as the UAS innovation center, building upon existing capabilities that integrate artificial intelligence and advanced systems for the Special Operations community.

Strategic Allocation of Resources

The Army is fine-tuning its requirements and specifications for the drones it aims to produce. “While we know we want a UAS, the specifics remain fluid,” Col. Martinez stated, acknowledging the need for continued dialogue to define capabilities precisely.

Rock Island personnel anticipate producing drone bodies that contribute to the Army’s target of delivering 1,000 UAS by the close of the current fiscal year, with scaled-up production planned by 2026. The push for an initial monthly output of 10,000 drones comes at an estimated cost of $197 million, with funding directed toward essential capabilities like brushless motors and wiring systems.

Reducing Dependence on Foreign Suppliers

The Army’s modernization initiative also aims to reduce dependency on foreign suppliers, particularly those in China and Taiwan, which currently produce 90% of UAS parts. Lt. Gen. Mohan emphasized the commitment to ensuring that domestically manufactured systems do not incorporate Chinese components. This strategy aligns with broader military objectives to secure supply chains for critical materials, including rare earth minerals and lithium.

Future Steps in Drone Integration

As the Army moves forward, a coordinated effort is required to ensure effective deployment and accountability for the drones produced. Prioritizing distribution to training facilities is essential for maintaining operational readiness. The first batch of 50 systems will be allocated to I Corps at Joint Base Lewis-McChord, signifying a pivotal step in bolstering U.S. capabilities.

As the Army embarks on an unprecedented acceleration in UAS production, the potential for operational impact is significant, setting the stage for enhanced readiness in addressing modern conflicts. This development promises to pivot U.S. military strategy towards a more agile and responsive operational framework in the years ahead.