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Exclusive: US Army 101st Airborne Division Develops 3D-Printed Small Drones for Air Assault Operations.
On January 21, 2025, the U.S. Army announced a significant milestone in its ongoing technological transformation, with the 101st Airborne Division (Air Assault) launching the production of small-unmanned aircraft systems (sUAS) using 3D printing. This innovative effort, driven by the EagleWerx Applied Tactical Innovation Center at Fort Campbell, aims to revolutionize drone manufacturing and is set to play a pivotal role in the Division's upcoming major training exercise, Operation Lethal Eagle.
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The small-unmanned aircraft system, 3D printed by the 101st Airborne Division (Air Assault), completes its inaugural flight on October 10, 2024, at Fort Campbell, Ky. This drone is scheduled for testing during Operation Lethal Eagle in the spring of 2025. (Picture source: U.S. Army)
The U.S. Army 101st Airborne Division is forging a new path in drone development, focusing on creating small UAS (Unmanned Aerial System) that are more versatile, durable, and cost-effective than previously fielded systems. The 3D printed drones are expected to provide tactical advantages, addressing the unique needs of air assault operations, and offer valuable lessons for future Army modernization efforts.
As the U.S. Army accelerates its transformation into a more agile, tech-driven force, the 101st Airborne Division is at the forefront of experimenting with and deploying advanced technologies. The Division's efforts to 3D-print sUAS at EagleWerx represent a paradigm shift in how drones are produced and integrated into military operations.
“This is bigger than simply printing parts. We are reshaping the sUAS enterprise at the tactical level,” said Col. (Promotable) Travis McIntosh, Deputy Commanding Officer for Support of the 101st ABN Division. “This initiative will affect how we do small UAS in the division, from airworthiness to parts ordering, to fielding and training.”
The emphasis on 3D printing goes beyond just prototyping. It introduces a new approach to drone development and logistics, particularly in terms of reducing time and costs for manufacturing and deploying sUAS. The Division’s decision to make use of advanced manufacturing capabilities at EagleWerx is a direct response to feedback from soldiers who requested drones that are not only more efficient but also easily replaceable.
The U.S. Army 101st's decision to develop these 3D-printed sUAS was made in collaboration with the 5th Special Forces Group (Airborne), which has been integral in pushing the requirements for these systems. Soldiers from both units requested drones that would be more versatile, durable, and, importantly, expendable—capabilities that existing systems often lacked. The new drones will be tested during Operation Lethal Eagle, where the Division will field 100 custom-made sUAS units.
"We are able to print these systems at a fraction of the cost of traditional models, without sacrificing operational functionality," said Capt. Andrew Blomquist, the 2nd Mobile Brigade Combat Team’s innovation officer. He emphasized the excitement within the Division to see these new, 3D-printed drones put to the test in the hands of soldiers during the exercise.
Operation Lethal Eagle is a 21-day training exercise designed to push the limits of the Division's capabilities, particularly in large-scale, long-range air assault (L2A2) operations. The event aims to prototype and test emerging Army technologies, enhance the lethality of soldiers, and build proficiency in complex, multi-domain operations. During the exercise, soldiers will conduct a range of missions that integrate these new sUAS into tactical operations. This will provide invaluable data for refining drone usage and manufacturing at the tactical level. The training is expected to showcase the practical benefits of 3D-printed drones, such as their ease of replacement in the field and lower costs for procurement, maintenance, and training.
The 3D manufacturing initiative is a reflection of the Army's broader strategy to modernize and improve its technological edge. As Col. McIntosh notes, the effort is part of an ongoing transformation that will make the Division’s drone systems more adaptable to ever-evolving mission requirements, from surveillance to electronic warfare.
While the U.S. Army 101st Airborne Division’s 3D-printed drones will first be tested during Operation Lethal Eagle, they are expected to be a permanent fixture within the Division’s technological arsenal. The success of the program could serve as a blueprint for other units in the U.S. Army, offering a new model for rapid, cost-effective drone manufacturing that can be easily scaled across other operational theaters.
As U.S. soldiers continue to experiment with and refine these new systems, the 101st’s venture into 3D printing is setting the stage for broader innovations in military drone development, offering a glimpse into the future of Army warfare—one where agility, speed, and innovation take center stage.