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US Navy 3D prints combat-ready drones, over 1,000 parts aboard aircraft carrier
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During a two-week transit to the RIMPAC 2026 exercise in Hawaii, the US Navy successfully operated a containerized 3D printing factory aboard the USS Essex. The xCell platform from Firestorm Labs produced 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 used as adversary aircraft in a counter-UAS exercise. Firestorm Labs highlighted that this capability reduces reliance on traditional supply chains, 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, as well as 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 from Firestorm Labs. Notably, production continued uninterrupted despite rough seas and waves reaching up to 12 feet during the journey.
Key Milestone for Expeditionary Manufacturing
In Firestorm's words, this additive manufacturing milestone using the xCell platform "just proved expeditionary manufacturing works in real conditions." The 3D printers on board produced a wide range of useful items on demand throughout the voyage.
xCell 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 Printed at Sea
The headline product from the range of items manufactured at sea was twelve quadcopter drones. These were Squall FPV drones, one of Firestorm Labs' key products. The NDAA-compliant Squall is designed for U.S. forces to "Print. Build. Fly. Dominate."
Squall drone specifications:
- Range: Up to 20 miles
- Flight time: Up to 42 minutes
- Top speed: 80 mph
- Payload capacity: 5.5 pounds
These same drones were flown as adversary aircraft in a counter-UAS exercise when the USS Essex arrived at RIMPAC.
Other Critical Parts Produced
While the drones may be the most newsworthy output from xCell, other essentials printed en route to Hawaii included:
- Apache helicopter rotor droop-stops — designed to prevent $500,000 rotor damage during at-sea operations
- Custom vacuum-hose coupling for life preserver testing, needed during the exercises
Crew-Requested Items
Rounding out the 1,000+ 3D-printed parts and spares were crew-requested gadgets and gizmos, including:
- Covers for electrical fittings
- A bracket for mounting Starlink
- Gauges for checking deck tie-downs
- And many more items
"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," Firestorm stated on social media. "Repairs that once meant days or weeks waiting on a resupply run can now happen in hours, on station."
Source
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U.S. Navy 3D-prints drones aboard USS Essex during RIMPAC transit