Firestorm Labs 3D-prints 12 drones aboard USS Essex in first at-sea trial
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Firestorm Labs manufactured 12 Squall drones and more than 1,000 components aboard the USS Essex during its Pacific voyage, marking the first at-sea 3D-printing of drones. The drones were subsequently flown as opposing aircraft in a counter-drone exercise during RIMPAC 2026. The trial allowed the Navy to bypass traditional supply chains, according to the company.
Onboard Drone Production
Firestorm Labs utilized its xCell containerized microfactory to print components and assemble 12 Squall first-person-view drones while the ship was underway. Service members assembled drones in conditions that included 12-foot waves, testing manufacturing robustness. The same equipment also produced mechanical test components and military repair parts needed by the crew, cutting the time and logistics required for resupply. According to Firestorm Labs, repairs that once took days or weeks could now be completed in hours.
Containerized Military Capabilities
The experiment aligns with a broader push for containerized military capabilities. Chief of Naval Operations Adm. Daryl Caudle announced a containerized capability campaign plan in March 2026, envisioning transportable containers with drones and weapons deployed across regions. The Pentagon has also pursued containerized munitions, with framework agreements announced in May involving Anduril, CoAspire, Leidos, and Zone 5. The Firestorm Labs trial provided sailors with hands-on experience operating a manufacturing system alongside other shipboard duties.
What's Next
The Navy is expected to continue evaluating containerized manufacturing systems following the successful trial, with potential wider deployment across the fleet. It remains unclear how quickly the technology can be integrated into standard naval operations given the need for crew training and ship modifications.
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Firestorm Labs 3D-prints 12 drones aboard USS Essex in first at-sea trial
