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Army Enhances Drone Warfare with 3D-Printed Technology

Alex by Alex
March 28, 2025
Reading Time: 2 mins read
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Army Enhances Drone Warfare with 3D-Printed Technology

HUNTSVILLE, Ala. – Russia’s invasion of Ukraine has highlighted the necessity for the U.S. Army to acquire a range of unmanned and counter-unmanned systems for drone warfare, alongside traditional powerful vehicles and artillery. General Jim Rainey, the head of Army Futures Command, emphasized the importance of integrating both high-tech solutions and affordable mass-produced options during his remarks at AUSA’s Global Force Symposium. He specifically referenced the effectiveness of inexpensive 30mm rounds for downing UAVs, even if it requires multiple shots.

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One innovative offering in this arena is a 3D-printed unmanned aerial vehicle (UAV) developed as part of the Army’s Low Altitude Stalking and Strike Ordnance (LASSO) program, which is expected to issue a request for proposals shortly. The drone, named the Hellhound S3, is turbojet-powered and has a design reminiscent of a fighter jet rather than a typical quadcopter. It boasts the capacity to carry various payloads, including weapons, sensors, and electronic warfare jammers.

According to Sheila Cummings, CEO of Cummings Aerospace, the LASSO program demands a UAV capable of loitering and executing precision strikes. The Hellhound S3 is engineered to provide maximum flexibility for soldiers to adapt to battlefield mission needs, weighing under 25 pounds and allowing for rapid payload changes in less than five minutes without the need for tools. The entire construction is 3D-printed, enabling quick manufacturing and repairs directly at the forward operating base.

Additionally, as the Army faces the increasing threat of drone swarms—a tactic heavily utilized by Russian forces in Ukraine—there is a pressing need for effective counter-drone systems. Rainey mentioned the prospect of using affordable ammunition to counter drones, while Leonardo DRS is advancing a counter-drone laser system designed to be mounted on a Stryker vehicle. Senior director Ed House noted that using a laser for targeting lower-cost drones could significantly reduce expenditure, as opposed to deploying expensive missiles against them.

In recent tests, the Blue Halo 26kW laser system demonstrated its capacity to engage drones effectively and was evaluated by the Army in December following a successful test in August. The system can operate continuously for two minutes and can take down drones in just a few seconds. It comes equipped with a built-in generator, eliminating downtime for recharging. The laser system, which operates alongside a larger counter-UAS capabilities including a 30mm cannon and multi-mission radar, is set for a live-fire exercise trial in June at Fort Sill, Oklahoma.

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