Navy Deploys Innovative Microfactory Aboard USS Essex to Produce 3D-Printed Drones at Sea

Firestorm Labs recently demonstrated a significant advancement in naval warfare technology by manufacturing over 1,000 parts and twelve of its proprietary Squall drones aboard the Wasp-class amphibious assault ship USS Essex. This milestone was achieved using a containerized microfactory known as xCell, which is designed to be deployed on U.S. Navy vessels to produce unmanned aerial systems and spare parts swiftly and efficiently.

The production process took place during the ship's transit towards RIMPAC 2026 in Hawaii, showcasing the potential for rapid deployment of critical equipment without relying on shore-based resupply operations. By utilizing this mobile manufacturing capability, the Navy can significantly reduce logistical burdens and enhance operational flexibility. Every part printed at sea means fewer resources are needed to transport materials across potentially contested waters.

Service members aboard the USS Essex played a crucial role in assembling these drones under challenging conditions, with waves reaching up to twelve feet high battering the ship throughout the process. These drones were then used as adversary aircraft during counter-drone exercises conducted as part of RIMPAC 2026. Additionally, mechanical test components and military repair parts necessary for maintaining the vessel's operational readiness were also produced using the xCell system.

This initiative aligns with the broader goals set by the Department of Defense (DoD) to enhance modular payload capabilities that can deliver mission-ready assets swiftly to any region in the world. Chief of Naval Operations Adm. Daryl Caudle announced the "containerized capability campaign plan" earlier this year, emphasizing the importance of transportable containers housing various defense technologies such as drones and weapons systems.

In May, the Pentagon further solidified its commitment to modular munitions by entering into framework agreements with several defense companies including Anduril, CoAspire, Leidos, and Zone 5. These contracts aim to acquire over ten thousand containerized missiles over a three-year period starting in 2027, marking the launch of the "Low-Cost Containerized Munitions (LCCM) program."

The successful deployment of xCell aboard the USS Essex highlights the Navy's strategic shift towards self-sustaining platforms capable of rapid adaptation and response. This development not only underscores the importance of autonomous technology in modern naval operations but also addresses critical logistical challenges faced by maritime forces operating far from home ports.