3D-printed drones built on a US Navy ship for the first time, potentially opening a whole new world of possibilities for future warfare

Firestorm Labs successfully produced 3D-printed drones aboard the USS Essex, a US Navy ship, during a Pacific voyage, marking the first time such manufacturing took place at sea. The company utilized its xCell containerized microfactory to manufacture over 1,000 drone components and assemble 12 Squall first-person-view drones. These drones were later utilized in a counter-drone exercise within the Rim of the Pacific (RIMPAC) 2026.

The manufacturing process took place while the ship encountered 12-foot waves, demonstrating the system's resilience in challenging environments. The company claimed that this capability reduces the need for resupply runs across contested waters, cutting fuel, aircraft hours, and personnel required to maintain operational readiness.

The trial also allowed Navy personnel to gain experience in maintaining manufacturing operations amid shipboard conditions and equipment requirements. As the Navy embraces containerized capabilities, this experiment further integrates additive manufacturing onto operating warships, potentially enabling the production of selected drones and replacement components when needed, especially for crews operating far from established bases.

However, the long-term reliability of such production during extended operations or in combat conditions remains to be seen.