Thursday, February 13, 2025

New 3D Printed Loitering Munition Targets US Military Trials


Alabama-based aerospace and protection producer Cummings Aerospace has accomplished flight trials for its new 3D printed, transportable, turbojet-powered loitering munition. 

The unmanned aerial car (UAV) Hellhound S3 is a kamikaze drone designed for long-range, precision strike missions towards armored autos, tanks, and fortified positions. Cummings developed the Hellhound to equip the US Military’s Infantry Brigade Fight Groups (IBCTs) with Armored Brigade-level fight energy.    

By integrating additive manufacturing with business parts authorised by the US Division of Protection (DOD), Cummings simplifies logistics whereas lowering prices. Regardless of its affordability, Hellhound S3 reportedly delivers the identical superior warfighting capabilities as conventionally manufactured programs. Weighing beneath 25 kilos, together with the car, launch canister, and floor management system, it allows single-soldier deployment, enhancing mobility and effectiveness on the battlefield

The Huntsville weapons producer will submit its new lethal armament to the US Military’s Low Altitude Stalking and Strike Ordnance (LASSO) program, set to kick off later this 12 months. Final 12 months, Military management requested $120.6 million from US lawmakers for its LASSO initiative because the Pentagon seems to restock its munitions arsenal.   

“The fashionable battlefield calls for velocity, and quadcopters and propeller-driven drones are gradual. In fight, our peer adversaries will exploit each second of Delay,” commented Cummings Aerospace Founder and CEO Sheila Cummings. “Hellhound’s jet-powered design ensures Infantry Brigade Fight Groups can act quicker–gathering intelligence and hanging essential targets deep within the contested areas earlier than the enemy has time to react.” 

Hellhound turbo-jet-powered loitering munition. Image via Cummings Aerospace
Hellhound turbo-jet-powered loitering munition. Picture by way of Cummings Aerospace.

3D printed loitering munitions improve Military warfighting   

Designed to reduce collateral injury with exact payload supply, Hellhound 3 helps standard warheads, digital warfare, and intelligence, surveillance, and reconnaissance (ISR) payloads. In line with Cummings Aerospace, troopers can field-swap payloads with out instruments in beneath 5 minutes, enhancing mission flexibility. The system’s modular design will permit it to combine further payloads and mission profiles required by LASSO.     

Throughout final month’s flight trials on the Pendleton Unmanned Plane Methods Take a look at Vary in Oregon, Cummings Aerospace efficiently validated the Hellhound 3’s efficiency towards preliminary LASSO necessities. The airframe and subsystems have been licensed at Know-how Readiness Degree 7 (TRL-7), demonstrating their reliability in operationally life like circumstances.

Throughout three flight assessments, the turbojet-powered munition surpassed 350 mph at half throttle, overlaying over 20 km whereas consuming simply 50% of its gasoline. Moreover, inert payload assessments confirmed the Hellhound 3’s capability to execute simulated strikes with a non-explosive warhead. The trials additionally assessed intelligence, surveillance, and reconnaissance (ISR) capabilities, together with Hellhound’s in-flight video transmission. In line with Cummings, the kamikaze drone carried out reliably in chilly temperatures, excessive winds, and snow, confirming its compatibility with numerous warzone environments.  

This builds on 12 earlier assessments in 2023 and 2024 which established the system’s core capabilities. The Alabama-based aerospace producer will now work to conduct further flight testing and convey the whole loitering drone system to TRL 7. It additionally plans to conduct further demonstrations for different clients.    

A US soldier launching a loitering munition. Photograph by way of Sgt. Gregory T. Summers, twenty second Cell Public Affairs Detachment/US Military.

Additive manufacturing bolsters US protection capabilities        

Cummings’ new kamikaze drone seeks to deal with the DOD’s rising demand for airborne munitions because it strengthens home provide chains. The Pentagon elevated its annual finances requests for missiles, munitions procurement, and associated analysis and growth from $9 billion in 2015 to $30.6 billion in 2024. Additive manufacturing, with its cost- and time-saving potential, is bolstering these efforts. 

On the finish of final 12 months, rocket engine producer Ursa Main and Virginia-based Raytheon Applied sciences accomplished profitable US Arm flight assessments for a long-range strong rocket motor (SRM). Ursa Main’s Lynx 3D printing expertise was used with Raytheon’s digital engineering capabilities to provide the SRM. Additive manufatcring has reportedly allowed the Colorado rocket engine maker to realize “unprecedented timelines,” with practically 300 SRM static check fires accomplished in 2024 alone.   

Elsewhere, Italian rocket and missile specialist Avio expanded SRM manufacturing for the DOD, with plans to triple manufacturing over the following 4-5 years. Whereas the corporate hasn’t confirmed the function of additive manufacturing, it actively makes use of 3D printing to provide propulsion programs. Specifically, Avio leverages Velo3D Sapphire 3D printers to provide high-strength, corrosion, and temperature-resistance elements in nickel-based alloy supplies. 

Who gained the 2024 3D Printing Business Awards?

All of the information from Formnext 2024

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Featured picture exhibits a Hellhound turbo-jet-powered loitering munition. Picture by way of Cummings Aerospace.

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