Navy's Hypersonic Missile Program Struggles with Manufacturing Hurdles

The Government Accountability Office (GAO) has reported significant challenges in the production of Lockheed Martin’s Conventional Prompt Strike (CPS) hypersonic missile for the U.S. Navy. Currently, the company can only produce six to seven missiles annually, falling short of the navy's goal of 12 units per year. These manufacturing issues stem from a combination of workforce shortages, contaminated parts, and complex design requirements that hinder efficient production.

The GAO first highlighted these challenges in its annual assessment of Pentagon acquisitions last year. The latest report provides more detailed insights into specific problems such as inconsistent work standards, inadequate parts inspection, and untagged expired materials. A 2023 Navy audit at the Lockheed Martin facility further corroborated these issues by identifying numerous quality assurance lapses.

Lockheed Martin was designated as the prime contractor for both the CPS program and the Army’s Long Range Hypersonic Weapon (LRHW) in 2023, with Dynetics manufacturing the common hypersonic glide body system used by both missiles. The Navy plans to deploy its hypersonic weapon on Zumwalt-class destroyers starting in 2027 and intends to integrate CPS onto Block V Virginia-class submarines around the early 2030s.

The Army’s LRHW, also known as Dark Eagle, is already being deployed from ground-based launchers. Despite initial delays due to flight test issues, the service began fielding its first battery at the end of 2025 and expects to deliver a second by early 2027. However, ongoing manufacturing challenges are threatening these timelines.

Among the reported issues are labor-intensive assembly processes that exceed expectations, leading to inefficiencies in production schedules. As of March 2025, the direct labor required for each missile was significantly higher than necessary to meet planned production rates. Additionally, parts contamination and incomplete kits have caused delays as technicians must disassemble missiles mid-production to address issues.

The workforce has also been a critical factor in these challenges. Technicians face overly complex work instructions that are difficult to follow, leading to high turnover rates among employees. New workers require nearly a year of training before they can operate independently, further complicating production timelines.

Lockheed Martin has acknowledged the issues and is implementing corrective actions but remains optimistic about overcoming these hurdles. The company stated it is enhancing manufacturing processes to meet the demands of both Navy and Army programs more efficiently. However, the GAO’s report underscores the need for a coordinated strategy across the Department of Defense to address shared hypersonic initiatives effectively.

The financial implications are substantial, with the CPS program alone now estimated at $41 billion over its lifecycle, up from an initial estimate of $31 billion in 2020. The Army plans to spend more than $10 billion on procuring 48 missiles and associated ground equipment for the LRHW. These costs highlight the importance of resolving manufacturing challenges promptly to avoid further delays and increased expenses.

The GAO’s findings emphasize the urgency for both military branches and Lockheed Martin to address these production issues swiftly, ensuring that hypersonic capabilities can be deployed as planned without compromising national security objectives.