For the first time, a containerized additive manufacturing factory aboard a US Navy amphibious assault ship produced flight-ready drones and hundreds of spare parts while underway to a major exercise. The USS Essex printed 12 Squall FPV drones and more than 1,000 components during its two-week transit to RIMPAC in Hawaii, proving that expeditionary manufacturing can function in rough seas and 12-foot waves.

What You Need to Know

The ability to 3D print critical parts and drones at sea reduces dependence on supply chains that can be disrupted by adversaries. The US Navy is exploring distributed manufacturing to keep ships operational in contested environments. Firestorm Labs’ xCell platform uses industrial HP Multi Jet Fusion printers and semi-automated assembly inside shipping containers. Repair and resupply that once took days or weeks can now happen in hours on station.

How the Production Worked at Sea

Firestorm Labs deployed its xCell expeditionary manufacturing platform for the first maritime run. The system fits inside two expandable 20-foot ISO containers or a single 40-foot equivalent. Inside, industrial HP Multi Jet Fusion polymer printers worked alongside semi-automated assembly stations to produce parts on demand.

  • Squall FPV drones: Twelve quadcopters with a 20-mile range, 42-minute flight time, 80-mph top speed and 5.5-pound payload capacity. These drones were later flown as adversary aircraft in a counter-UAS exercise at RIMPAC.
  • Apache helicopter spares: Rotor droop-stops designed to prevent $500,000 rotor damage during at-sea operations. The crew also printed a custom vacuum-hose coupling for life preserver testing.
  • Crew-requested items: Covers for electrical fittings, a bracket for mounting Starlink, gauges for checking deck tie-downs and dozens of other practical gadgets.

Throughout the voyage, the xCell platform kept producing despite rolling seas and 12-foot waves. Firestorm Labs stated that the milestone “just proved expeditionary manufacturing works in real conditions.”

Why This Matters

This demonstration shifts the logistics paradigm for naval operations. A ship that can manufacture its own drones and replacement parts no longer must wait for resupply convoys or airlift. In contested waters, every part printed on deck is one that does not need to be flown or shipped across dangerous territory. The US Navy cuts fuel, aircraft hours and personnel required to keep a ship operational. For repairs that once meant days or weeks of delay, the turnaround now shrinks to hours. The ability to print NDAA-compliant Squall drones on demand also gives commanders immediate access to reconnaissance and counter-UAS assets without relying on external deliveries. As the Navy continues to test distributed advanced manufacturing, the USS Essex voyage sets a new benchmark for self-sufficient naval warfare.