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US Navy 3D prints combat-ready drones and over 1,000 parts aboard aircraft carrier
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During a two-week transit to RIMPAC 2026 in Hawaii, the USS Essex hosted a containerized factory using Firestorm Labs' xCell expeditionary manufacturing platform. The system 3D-printed a dozen flight-ready Squall FPV drones, capable of 80 mph and a 20-mile range, along with over 1,000 parts including critical Apache helicopter rotor droop-stops and a custom vacuum-hose coupling for life preserver testing. Production continued despite rough seas and 12-foot waves. The drones were later flown as adversary aircraft in a counter-UAS exercise at RIMPAC. Firestorm Labs highlighted that on-demand printing reduces reliance on supply chains across contested waters, cutting repair times from days or weeks to hours.
Source report
During a two-week transit to RIMPAC 2026 in Hawaii, a containerized factory aboard the USS Essex 3D printed a dozen flight-ready drones and over 1,000 parts, including vital spares for Apache helicopters.
According to 3D Printing Industry, this was the first maritime deployment of the xCell expeditionary manufacturing platform, developed by Firestorm Labs. Notably, production continued uninterrupted despite rough seas and waves reaching up to 12 feet.
Key Achievement
Firestorm described the milestone as one that "just proved expeditionary manufacturing works in real conditions." The 3D printers aboard produced a wide range of useful items on demand during the journey.
Platform Specifications
The xCell containerized production line occupies just two expandable 20-foot ISO containers—or a single 40-foot equivalent. Inside, it houses industrial HP Multi Jet Fusion polymer printers alongside semi-automated assembly stations.
Drones Produced at Sea
The headline output was twelve Squall FPV drones, a key Firestorm Labs product. Key specifications of the NDAA-compliant Squall include:
- Range: Up to 20 miles
- Flight time: Up to 42 minutes
- Top speed: 80 mph
- Payload capacity: 5.5 pounds
Upon the USS Essex's arrival at RIMPAC, these same drones were flown as adversary aircraft in a counter-unmanned aerial system (UAS) exercise.
Other Critical Parts Manufactured
Beyond drones, the crew printed essential spares during the transit, including:
- Apache helicopter rotor droop-stops — designed to prevent $500,000 rotor damage during at-sea operations
- Custom vacuum-hose coupling — used for life preserver testing during exercises
Additional Crew-Requested Items
The 1,000+ 3D-printed parts and spares also included various crew-requested items, such as:
- Covers for electrical fittings
- A bracket for mounting Starlink
- Gauges for checking deck tie-downs
- Numerous other gadgets and gizmos
Operational Impact
Firestorm highlighted the logistical advantage on social media: "Every part xCell printed on deck is one that doesn't need to be flown or shipped across contested waters — cutting the fuel, aircraft hours, and personnel it takes to keep a ship operational. Repairs that once meant days or weeks waiting on a resupply run can now happen in hours, on station."
Source
Latest from Tom's HardwareNeutral / independent
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U.S. Navy 3D-prints drones aboard USS Essex during RIMPAC transit