FORT CARSON, Colo. — A distinct hum and sharp buzz slice through the air inside the Ivy Eagle’s “Monster Garage.” The sounds emanate from a football-sized quadcopter, its rotors a blur as it expertly maneuvers around a complex, custom-built obstacle course.

The modern battlefield demands agility, adaptability, and technological superiority. Small unmanned aerial systems, sUAS, and 3D printing, also called additive manufacturing, technology have emerged as critical assets in achieving these objectives, providing essential reconnaissance, surveillance, target acquisition, electronic warfare and logistical support capabilities.

Pilots from the 4th Infantry Division’s sUAS Innovation Platoon, the “Dragonflies”, practice their maneuvering skills at the “Monster Garage” with the use of laptop-based simulators before progressing on to the obstacle course in the warehouse and completing larger field exercises to demonstrate how sUAS are playing a crucial role in the operational environment.

Brig. Gen. Eugene Ferris, the division’s former deputy commanding general for maneuver, said that the future of modern warfare will depend on the lethal integration and the effective deployment and sustainment of sUAS in dynamic and often contested environments, which are paramount for mission success.

Small Unmanned Aerial Systems

In military operations, sUAS serve many critical roles, providing real-time intelligence, enabling precision strikes, conducting electronic warfare, and even facilitating resupply in challenging environments.

The effectiveness of the sUAS Innovation Platoon, 6th Squadron, 17th Cavalry Regiment, 4th Combat Aviation Brigade, 4ID, in these varied and crucial roles is further amplified by the ability to tailor their designs for specific, demanding environments.

“For the 4ID and 4CAB, the ability to rapidly prototype and adapt sUAS designs is critical when operating in diverse and complex environments”, said 1st. Lt. Nicholas McDonald, platoon leader for the Dragonflies. “The performance characteristics of these systems extended flight endurance for persistent surveillance, low observability for stealth and robust construction for survivability.”

For the division, these advantages translate into tangible operational benefits: customizing sUAS to carry specific payloads or intelligence packages for information gathering, quickly prototyping and testing new sUAS configurations and integrations during training exercises to adapt to future threats.

The dynamic nature of military operations often necessitates swift responses to emerging threats or rapidly evolving tactical situations, empowering the 4th Infantry Division and the broader military to quickly translate urgent operational needs into tangible solutions for sUAS.

Additive Manufacturing

Additive manufacturing, or AM, is a transformative technology that revolutionizes how the military develops, deploys and maintains its sUAS fleets, offering unprecedented agility, customization and enhanced operational readiness.

Beyond conventional prototyping, AM enables the production of complex, lightweight components crucial for maximizing the flight performance of sUAS, reducing their signature and increasing their payload capacity. These demanding requirements necessitate the use of advanced materials and highly optimized designs, areas where AM offers significant advantages over traditional manufacturing methods.

Ferris explains that AM technologies offer specific benefits for military applications. The inherent flexibility of AM allows for integrating features that enhance functionality and survivability in contested environments.

Additive manufacturing constructs three-dimensional objects directly from a digital file. The process begins by digitally slicing the 3D model into numerous thin, horizontal cross-sections. Following these sliced instructions, the 3D printer builds the object layer by layer from the bottom up. This involves extruding melted material like plastic filament and selectively curing liquid photopolymer resin with light.

Soldiers can rapidly produce replacement parts for damaged drones, fabricate specialized tools and fixtures for maintenance at the battalion level, and even create custom adapters or mounts for unique mission requirements directly in the field, significantly saving Soldiers’ time and the division’s maintenance costs.

Such advancements in operational readiness and flexibility through AM directly support the framework established by the Ivy Division’s priorities.

Integrating the Ivy Division Priorities

Two of the division’s priorities — lethal teams and peak partners — play a significant role in sUAS and AM.

Ferris said AM empowers the 4ID to translate urgent operational needs into tangible solutions for sUAS quickly. AM enables the rapid design and fabrication of prototype sUAS or specialized components to address specific battlefield challenges.

Ferris said that units such as the 4CAB’s Dragonflies and the 10th Special Forces Group have made significant strides in integrating sUAS into training, ensuring that 4ID remains prepared for the challenges of modern warfare.

These technologies directly enhance the priorities of lethal teams by equipping Soldiers with superior situational awareness with sUAS reconnaissance and surveillance. Additive Manufacturing ensures these critical eyes-in-the-sky and other essential gear can be rapidly repaired and maintained even in austere environments, keeping teams equipped, informed and deadly.

To maintain this technological edge and ensure a future of skilled personnel, the 4th Infantry Division actively engages with the local community, especially in STEM education.

Keri Brandt, 4ID’s Ivy Human Capital Campaign manager, said the division’s collaboration with District 8 highlights its well-established connections within the wider Front Range community. Brandt explained that a significant part of their partnership development strategy includes a mentorship program for students in science, technology, engineering and mathematics. This program brings students to the military installation for on-site visits, allowing them to see directly how the 4ID applies coding, engineering, and technological principles in the operation of drone and robotics systems. Brandt explains that 4ID and Fort Carson service members participate in district events to help facilitate STEM competitions, fostering student engagement and learning opportunities.

The future holds significant promise for integrating AM and sUAS. Empowering units like the sUAS Innovation Platoon with organic manufacturing capabilities and integrating artificial intelligence and machine learning could lead to automated design optimization for battlefield repairs.

Ultimately, the potential for Soldier-level customization and repair of sUAS using user-friendly AM systems could revolutionize battlefield logistics and operational flexibility.

As AM and sUAS technology continues to mature and integrate with other advancements, its role in empowering the Ivy Division and the broader military with cutting-edge aerial capabilities will continue to grow, ensuring a decisive edge in future conflicts.

By CPL William Rogers

ROCK ISLAND ARSENAL, Ill. – As the conflict in Ukraine has demonstrated, the battlefield of the future will be defined by the innovative and widespread use of unmanned aerial systems, and the ability to rapidly produce and deploy these systems at scale will be crucial to maintaining a tactical advantage in future conflicts.

“The U.S. Army recognizes the changing dynamics of warfare and is fully committed to staying ahead of the curve,” said Col. David Guida, commander of Rock Island Arsenal-Joint Manufacturing and Technology Center. “We are investing heavily in our Organic Industrial Base, harnessing its agility and innovation to develop and field advanced capabilities like these 3D-printed drones. At RIA-JMTC, our unique blend of cutting-edge technology and skilled artisans is leading the charge in this critical effort to shape the future of warfare.”

Through initiatives like Transforming in Contact, the Army is fielding new technologies and transforming how it develops, tests and integrates those technologies onto the battlefield. TiC prioritizes addressing immediate needs by enabling “in-contact experimentation”—putting cutting-edge technology directly into the hands of Soldiers and empowering them to innovate and adapt in real-world scenarios. This approach fosters a culture of calculated risk-taking and rapid Soldier feedback, ensuring that solutions are not only technologically advanced but also practical and effective on the modern battlefield. By focusing on near-term solutions and integrating emerging technologies, TiC enables Army units to rapidly test organizational changes and stay ahead of our adversaries, ensuring they are ready to fight and win in an increasingly complex and challenging operational environment. RIA-JMTC is partnering with multiple units in the field and the Combat Training Centers to share and provide technical data and lessons learned to help all improve.

This flexible and adaptive process is illustrated by the development of 3D-printed drones. RIA-JMTC is actively preparing to build the capacity for large-scale production of 3D-printed drones, working in close collaboration with other key OIB facilities, such as Tobyhanna Army Depot. This collaborative approach, harnessing the unique strengths and expertise of various OIB sites, is key to the Army’s strategy for rapidly developing and fielding advanced UAS capabilities. This directly supports TiC’s goal to accelerate the innovation and experimentation of new systems at scale to preserve our technological edge.

“This project is a testament to the enduring spirit of American ingenuity and the Army’s unwavering commitment to staying ahead of the technological curve,” said Guida. “Our team at RIA-JMTC is dedicated to producing high-quality, on-time readiness solutions for the Warfighter, constantly pushing the boundaries of what’s possible in support of those on the front lines. This 3D printed drone initiative embodies that commitment, showcasing our ability to rapidly adapt and deliver cutting-edge solutions that will directly impact the future of warfare.”

The initiative was sparked by a collaborative proof-of-concept project with the 101st Airborne Division (Air Assault), which highlighted the potential of 3D printing for rapidly prototyping and producing customized tactical drones tailored to specific mission needs. This initial project served as a valuable learning experience, demonstrating the viability of RIA-JMTC’s 3D-printed drone production capabilities and revealing the power of collaboration within the OIB.

“The history of the 101st Airborne Division is a testament to the courage, ingenuity and unwavering spirit of the American Soldier,” said Maj. Gen. Brett Sylvia, commanding general of the 101st Airborne Division (Air Assault). “These 3D printed drones are the latest of many exciting emerging technologies we are implementing under our continuous and iterative TiC. They are the beginning of a user-driven, division-enabled force multiplier that will empower our Screaming Eagles to write the next chapter in the evolution of vertical envelopment.”

Building on these initial successes, RIA-JMTC produced smaller drones from the 2nd Calvery Regiment with less pieces to again showcase its rapid production capabilities. The factory is now focused on preparing for full-scale production to meet the Army’s broader and rapidly expanding UAS needs. The factory is actively researching and evaluating various drone designs to ensure they are prepared when the Army provides the requirements. This research involves close collaboration with other experts within the OIB’s research and development community to identify designs that offer the optimal balance of capability, adaptability and cost-effectiveness.

“The OIB must support current unit readiness across the force, maintain the ability to surge and modernize and retool to sustain the next generation of equipment,” asserted Greg Lupton, RIA-JMTC deputy commander. “This project, demonstrating how Arsenals like RIA-JMTC directly respond to urgent Warfighter needs, highlights this critical role. By manufacturing and fabricating vital components and systems, Arsenals ensure our Soldiers have the utmost confidence in their equipment and are prepared to face any challenge on the battlefield.”

This collaborative approach is exemplified by RIA-JMTC’s partnership with Tobyhanna Army Depot, the Army’s Center of Industrial and Technical Excellence for Command, Control, Communications, Computers, Intelligence, Surveillance, and Reconnaissance (C4ISR) and Electronics, Avionics, and Missile Guidance and Control, and the Air Force Technology Repair Center for Tactical Missiles, Rigid Wall Shelters and Portable Buildings. Tobyhanna brings unparalleled expertise to the project, and their artisans will install the sophisticated electronics, sensors and mission-critical internal systems that will bring the drones to life, leveraging their deep experience in C5ISR, avionics and missile guidance systems.

“This partnership with RIA-JMTC leverages Tobyhanna’s core strengths as the Department of Defense’s leading provider of C5ISR readiness for the joint Warfighter,” said Col. James L. Crocker, Tobyhanna’s commander. “Our skilled workforce and state-of-the-art facilities are prepared to equip 3D printed drones with the advanced technological capabilities they need to provide a decisive edge on the battlefield.”

In addition to this ongoing research and development effort, RIA-JMTC is working to compile Technical Data Packages from the Army, which will help define the specific types and quantities of drones required to meet the demands of the future battlefield. This TDP will provide the critical specifications and requirements that will guide the final stages of production planning and ensure that the drones produced by RIA-JMTC are precisely tailored to meet the needs of the Warfighter.

“This project is about investing in the future of the Army and ensuring that our Soldiers have the tools they need to succeed in any mission, on any battlefield,” said Guida. “We are not just building drones; we are building the future of Army readiness.”

RIA-JMTC, in close coordination with Tobyhanna and other key OIB partners, is working to be fully prepared to rapidly produce and deliver these critical assets to the Warfighter. This agile and collaborative approach ensures that the Army can rapidly adapt to evolving threats and maintain its technological edge on the dynamic battlefields of the future.

“This is about more than just drones,” Lupton added. “This is about the Army’s commitment to leveraging the full potential of the OIB to maintain its technological edge in an era of rapidly evolving threats. The partnerships we are forging today will be essential to ensuring our nation’s security for decades to come.”

By Kendall Swank