Drones and 3D printing are two technologies that have already changed many aspects of our modern world. Warfare has seen some revolutionary changes, especially in active war zones like Ukraine.
However, like most things in war, a tool must be reliable, robust, and readily available to frontline operators with little to no delay for it to be helpful. In an ideal world, soldiers should be able to make (or customize) stuff they need as and when required.
This is especially true for replacement parts for things like drones, and 3D printing could be instrumental here. So, would combining these two revolutionary technologies benefit the battlefield?
Let’s take a look.
3D printing on the frontlines
Imagine the possibilities that would open if soldiers could print drones and drone parts on demand on the frontlines. Or be able to innovate new features to customize them on the fly?
Such a capability would not only help frontline troops adapt to rapidly changing situations quickly under their initiative, but it would also help them become more self-sufficient.
Believe it or not, the U.S. Army has started to explore just this. According to a U.S. Army Combat Capabilities Development Command (DEVCOM) report, integrating additive manufacturing (AM), AKA 3D printing, into frontline operations could prove a game-changer.
According to this report, 3D printing could dramatically improve soldiers’ tactical agility by allowing the rapid fabrication of essential tools, equipment, and, notably, drones, exactly where they are most needed.
More importantly, such plans are not just theoretical either. In fact, the U.S. Army has also started implementing them. According to recent reports, the 101st Airborne Division (Air Assault) has already begun experimenting with the idea and training troops.
To this end, they have already started experimenting with 3D printers for small-unmanned aircraft systems at the EagleWerx Applied Tactical Innovation Center at Fort Campbell.
“This is bigger than simply printing parts. We are reshaping the sUAS enterprise at the tactical level,” explained Colonel Travis McIntosh, deputy commanding officer for support of the 101st Airborne Division. He added that it would impact “how we do small UAS in the division, from airworthiness to parts ordering, to fielding and training.”
But this is only just the beginning of something potentially much larger.
Benefits of 3D printed drones
“An army,” the famous saying goes, “marches on its belly.” This is as true today as it has been since the advent of warfare itself. However, this adage refers not only to actual food but also to military logistics as a whole.
Supply chains must be constantly protected and maintained to keep the main army in the field for extended periods. Failure to do so can lead to bottlenecks that can threaten an army’s fighting fitness and could be the difference between victory and defeat.
Regarding drones, supply chain issues can result in delayed deployment or replacement parts taking days, weeks, or even months to arrive where needed. This could severely hamper operational momentum and reduce overall mission effectiveness.
To this end, the U.S. Army Research Laboratory (ARL) is experimenting with introducing portable, ruggedized 3D printers that enable frontline personnel to produce replacement parts as needed. This could, in theory, significantly streamline maintenance processes and enhance operational efficiency.
It could also be readily adapted for drones.
The tactical benefits of this are clearly obvious. It would, for example, drastically reduce repair lead times, enabling units to maintain operational continuity, especially in remote or austere battlefields.
Defense News has previously highlighted that frontline additive manufacturing can turn weeks-long waits for replacement parts into hours or days. This would fundamentally change how logistics are managed and significantly improve combat readiness.
For example, drone propellers or camera mounts, which are frequently damaged during operations, could be replaced with printed components without having to order parts and wait for them to arrive. This technology could also provide “out-of-print” parts that are no longer supplied or supported by an original manufacturer.
War: the mother of all invention
As we mentioned before, another significant benefit of providing 3D printing capabilities to field personnel is the ability to adapt to situations on the fly. Soldiers could, in theory, use 3D printing to create mission-specific drones tailored to precise tactical needs.
Such an ability would dramatically improve tactical responsiveness, providing commanders with tailored solutions as mission demands evolve.
According to a RAND Corporation analysis, the adaptability afforded by additive manufacturing presents a substantial strategic advantage by allowing commanders greater flexibility and precision in executing complex military operations.
Yet another significant benefit is the reduction of dependency on traditional and potentially vulnerable supply chains. By printing components directly in combat zones, the Army decreases its exposure to supply-chain disruptions or hostile actions targeting logistics routes.
The Department of Defense’s 2022 Additive Manufacturing Strategy also identified the potential benefits, emphasizing the need to leverage AM to ensure logistical robustness and strategic resilience in contested or remote environments.
The grass is not always greener
But like anything, there are only compromises, never complete solutions. 3D printing for drone warfare is no exception.
One key hurdle is ensuring the reliability and durability of printed components in harsh battlefield conditions. As the Army Futures Command noted, verifying the performance standards of additively manufactured parts remains complex.
This would be particularly critical for flight-critical drone components, which must withstand rigorous operational environments. Moreover, training soldiers to operate sophisticated 3D printing equipment under combat conditions effectively requires significant investment.
The logistical footprint of transporting printing materials, such as filament and resins, into austere environments also poses a practical challenge. This would mean that more traditional military supply chain management would remain critical.
Unless a reliable way could be found to produce the raw materials in situ. Any equipment would also need to be portable enough to make them useful, and rigid enough to survive in the field.
Furthermore, cybersecurity poses another very important potential pitfall. Digitized blueprints and 3D-printed files can become targets for cyber threats or espionage.
As such, to make this work, the Army would have to develop robust cybersecurity protocols to safeguard additive manufacturing processes against adversarial interference, particularly in digitally contested battlefields.
Is it just a pipe dream?
For this concept to become a reality in the near future, the U.S. Army would need to overcome the above and other issues, such as ensuring adequate power supplies, maintaining equipment reliability, and mitigating environmental factors (such as dust, extreme temperatures, and humidity).
But, if achieved, the tactical and logistical advantages of the US Army’s adoption of field-deployable drone manufacturing are undeniable. This innovation reduces supply chain vulnerabilities and enhances operational readiness and mission adaptability.
While the hurdles related to reliability, training, logistical support, and cybersecurity are significant, ongoing advancements and strategic planning are well-positioned to address these challenges.
As such, field-based additive manufacturing stands poised to redefine the future of military operations, promising greater tactical flexibility and strategic resilience for US armed forces.
But, that is just out two cents, what do you think?