How to Quickly Acquire Affordable Military Drones by 3D Printing on the Field

The gap between the US and its global competitors in the production of military drones is substantial. A startup based in San Diego, Firestorm Labs, has put forth an innovative solution to close this gap by bringing 3D printing technology directly to the battlefield.

Firestorm has developed a compact, mobile manufacturing facility capable of producing a wide range of drone models and components. These factories are housed within two 20-foot shipping containers, each containing state-of-the-art HP industrial printers. The setup is efficient, requiring only two to four personnel to operate, and is capable of producing roughly 17 small to mid-sized drones each week. Firestorm also offers two of its own drone designs.

The call to innovate in the drone sector has been spearheaded by Defense Secretary Pete Hegseth, who has urged the tech industry to help the US catch up in drone production. The initiative has attracted significant interest from Silicon Valley. Last year, Firestorm secured a substantial $100 million contract with the US Air Force for the development and research of unmanned aerial systems. This year, the company raised $47 million in Series A funding from noteworthy contributors such as New Enterprise Associates and Lockheed Martin Ventures.

Chad McCoy, one of Firestorm's co-founders and chief growth officer, reflects on his 23-year military career where he served as a pararescueman. During a recent interview, he recounted how he longed for a simple, waterproof box to power medical devices—an item the military took four years to develop. Now, McCoy is dedicated to speeding up military projects through rapid production and iteration.

Adapting to Drone Shortages

Chinese manufacturing, led by DJI, produces tens of millions of drones annually, according to drone industry consultant Bobby Sakaki, CEO of UAS Nexus. The US finds itself in a race to increase its drone capabilities, with one significant hurdle being the scarcity of parts necessary for battlefield drones.

The journey of Firestorm's co-founders, Dan Magy and Ian Muceus, began with a proposal of mass-producing cost-effective cruise missiles. Magy's experience includes founding Citadel Defense Company, a successful counter-drone technology firm, while Muceus brought expertise from his role in aerospace manufacturing at a 3D printing startup. Together with McCoy, they pivoted to focus on drones, recognizing their growing importance in conflicts like those in Ukraine.

Mobilizing Production Facilities

A significant aspect of Firestorm's innovation is the xCell—mobile manufacturing units capable of operating across diverse environments thanks to their adaptable design and climate-tested HVAC systems. The sides of the containers can expand to create additional work space.

Although currently there are a limited number of xCells, the company plans to deploy more, including one in the US Indo-Pacific Command by early 2026. Firestorm's drones, 'Tempest' and 'Hurricane,' offer customization through open software development tools.

Beyond drones, McCoy envisions the xCell technology potentially being used to produce medical devices and prosthetics, transforming both the nature of combat and logistical strategies.