Beehive uses 3D printing for Frenzy propulsion series in UAS platforms

Beehive Industries reports the completion of high-altitude tests for its 200-lbf Frenzy engine and thus sees the prerequisites for flight testing in early 2026 as fulfilled. The company develops jet engines for unmanned aerial vehicles in the defense sector and pursues a clear 3D-printing focus. Production follows an “additive-first” approach, in which structural and hot-section components are designed for additive processes from the outset.

The latest test campaign took place at a government test facility in Ohio under altitude conditions and included ignition trials, acceleration maneuvers and endurance runs over a mission-equivalent profile. According to the company, thrust, high-altitude ignition capability, operational stability, turbine inlet temperatures and specific fuel consumption were confirmed across the entire flight envelope.

“The milestone confirms Frenzy’s readiness for flight integration,” said David Kimball, Chief Technology Officer at Beehive Industries. “In less than a year, we’ve gone from concept to proven high-altitude performance, and we’re doing it ahead of schedule because of the talented and determined team at Beehive. Frenzy is now flight-ready, and our production system is ready to scale alongside it.”

At the core of the strategy is the extensive use of metal powder bed fusion and other additive processes that enable a high degree of functional integration. According to Beehive, development cycles can be significantly shortened compared to conventional engine manufacturing, because design changes are implemented directly in the CAD model and produced without extensive tooling modifications. At the same time, production routes with fewer machining steps and less material waste are to be established. In parallel, the company is scaling its sites in Denver, Cincinnati and Knoxville for initial series production.

“This test campaign not only demonstrates the full potential of our engine, but also how we move with speed through a highly iterative, cross-functional development program,” Kimball added. “Each milestone strengthens our confidence in the architecture, our ability to deliver on our commitments, and the disruptive path we’re charting for next-generation propulsion. We’re not just accelerating development timelines, we’re ensuring America’s warfighters have the technology they need, when they need it most.”

The Frenzy family covers a thrust range from 100 to 300 lbf and targets jet-powered unmanned systems where compact design and efficient part-load operation are paramount. The basis is a contract awarded in October 2024 by the US Air Force Rapid Sustainment Office in cooperation with the University of Dayton Research Institute. With the altitude program completed, integration into a first flight vehicle is now within reach, before the engine is transitioned into small-series production.