The US Army is currently developing low-cost, 3D-printed drones that can recognize electromagnetic signatures. The first test flights are to take place next month as part of a maneuver in Poland. The aim is to test the operational capability of small unmanned systems that can be manufactured independently of the defense industry. The first prototypes were developed by the 2nd Multi-Domain Effects Battalion based in Mainz-Kastel.
The seven drones produced to date are equipped with sensors to detect electromagnetic radiation. These can be used to locate cell phones, routers, WLAN signals and radars, among other things. Information that is not accessible to cameras. The technology is intended to help detect enemy activities without them being physically visible. An innovation team led by Chief Warrant Officer 2 Chris Lehr is responsible for the development and adaptation of the drones.
The manufacturing costs per unit are around 2,000 to 3,000 US dollars – well below the prices of commercially available military quadcopters, which can cost up to 28,000 US dollars. This is made possible by the use of FDM 3D printers, which the team uses to produce sustainable aerospace frames. The unit manufactures the drones directly on site and develops both the design and the printing process independently.
The technical maturity level is still in the development stage. According to Lehr, initial tests were not successful, but led to improvements in the design. The team has now documented over ten successful flights. One challenge remains the lengthy approval process by the Ministry of Defense, which sometimes takes several months.
Another problem is the procurement of components. Although most components are commercially available, they can only be sourced from certain countries – which, according to Lt. Col. Aaron Ritzema, leads to higher costs and longer procurement routes. Nevertheless, the team sees in-house production as a strategically important capability. In the long term, such systems could increase operational readiness by producing them at short notice and in a decentralized manner.
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