US Navy 3D prints combat-ready drones and 1,000+ parts aboard aircraft carrier during exercise — containerized factory fabricated 80-mph FPVs and critical spares despite rough seas and 12-foot waves

During a two-week transit to RIMPAC 2026 in Hawaii, a containerized factory aboard the USS Essex 3D printed a dozen flight-ready drones, as well as over 1,000 parts including vital spares for Apache helicopters. 3D Printing Industry reports that this was the first maritime run of the xCell expeditionary manufacturing platform from Firestorm Labs. Furthermore, production wasn’t halted by the rough seas and up to 12 ft waves endured during the journey.

In Firestorm’s words, this additive manufacturing milestone using the xCell platform “just proved expeditionary manufacturing works in real conditions.” The 3D printers on board produced a plethora of useful things during the journey, on demand.

xCell’s containerized production line takes up just two expandable 20-foot ISO containers, or a single 40-foot equivalent. Inside are industrial HP Multi Jet Fusion polymer printers alongside semi-automated assembly stations.

Our headlining pick from the range of products that were manufactured at sea was the twelve quadcopter drones. These were Squall FPV drones, one of Firestorm Labs’ key products. The NDAA-compliant Squall is designed for U.S. forces to “Print. Build. Fly. Dominate.”

Squall has a range of up to 20 miles, a flight time of up to 42 minutes, a top speed of 80 mph, and can carry a 5.5-pound payload. These same drones were flown as adversary aircraft in a counter-UAS exercise when the USS Essex arrived at RIMPAC.

Drones might be the most newsworthy output from xCell, but other essentials that the crew printed en route to Hawaii included printed Apache helicopter rotor droop‑stops, designed to prevent $500,000 rotor damage during at‑sea operations. Another spare part highlighted by the source that was needed during the exercises was a 3D-printed custom vacuum‑hose coupling for life preserver testing.

Making up the 1,000+ 3D-printed parts and spares were crew-requested gadgets and gizmos like covers for electrical fittings, a bracket for mounting Starlink, gauges for checking deck tie-downs, and lots more. “Every part xCell printed on deck is one that doesn’t need to be flown or shipped across contested waters — cutting the fuel, aircraft hours, and personnel it takes to keep a ship operational,” boasted Firestorm on social media. “Repairs that once meant days or weeks waiting on a resupply run can now happen in hours, on station.”