Firestorm Labs Conducts Onboard Drone Manufacturing Tests with U.S. Navy
Firestorm Labs Demonstrates 3D Printing Capabilities Aboard USS Essex
More than 1,000 UAV Components Produced During Military Exercise
By DRONELIFE Features Editor Jim Magill
Firestorm Labs, a manufacturer based in San Diego, showcased its 3D printing technology by producing over 1,000 drone components aboard the USS Essex during a two-week voyage to the Rim of the Pacific 2026 (RIMPAC) military exercise in Hawaii. The components were utilized to assemble Firestorm’s Squall UAVs for target practice exercises.
Demonstration of Onboard Manufacturing
In an interview, Firestorm CEO Dan Magy emphasized the significance of the demonstration, stating that it enables the Navy to manufacture its own drones and equipment at sea, reducing reliance on logistics from shore or other vessels. He noted the Navy’s concerns regarding traditional logistics, particularly in contested environments.
“The phrase they use is contested logistics, and they believe that our solution is going to be integral in helping to solve some of these contested logistics challenges,” Magy explained, referencing operational difficulties in areas like the Strait of Hormuz.
Challenges and Achievements at Sea
During the exercise, Firestorm’s xCell additive-manufacturing equipment successfully operated under challenging maritime conditions, including peak Sea State 5 with 12-foot waves. The equipment was used to print parts necessary for assembling 12 Squall UAVs, which were then deployed as “red cell” drones in simulated military exercises.
In addition to UAV components, the Firestorm team printed repair parts requested by the USS Essex crew, addressing equipment losses and shortages. Notable items included:
- Rotor-guard droop stop for an Apache helicopter
- Vacuum adapter for an inflatable life-preserving unit (LPU)
- Custom gauges for deck tie-down inspection
- Reverse-engineered valve handwheels
- Starlink deployment mount
Training and Future Applications
After spending 12 days at sea, the Firestorm team continued their 3D printing efforts at Schofield Barracks on Oahu, where they trained military personnel, including Marines from the 3rd Light Armor Reconnaissance Battalion, on the use of the 3D printing technology.
The xCell equipment, which utilizes HP Multi Jet Fusion printers, is designed for compactness, allowing it to be used on smaller vessels. Currently, it can be transported in two 20-foot shipping containers, with plans to redesign it for transport in a single container.
Magy stated, “Our goal is to get as much of this equipment onto US Navy ships as possible because it’s clearly solving real needs, which is manufacturing at the point of need.”
Broader Implications for Military Logistics
Firestorm has sold several xCell units to various branches of the U.S. military and other government agencies, including the U.S. Border Patrol and civilian emergency response organizations. The technology has also attracted interest from the oil and gas industry.
According to Firestorm, the use of additive-manufacturing equipment aboard U.S. vessels can significantly enhance military preparedness by saving time and resources. The ability to print parts on deck reduces the need for resupply missions, allowing for quicker repairs and maintaining operational readiness.
“One of the biggest complaints that we’ve been addressing for the United States Army is with both their military and their commercial drones. When they break, the lead time to get some of these parts is massive. And we’re filling in the gap,” Magy concluded.