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US Navy Tests 3D Printing Custom Drones On Its Ships

itwbennett writes: Researchers at the Naval Postgraduate School are testing the use of 3D printers on ships to produce custom drones outfitted for specialized missions. The idea, said Alan Jaeger, a faculty research associate at the school, is that ships could set sail with kits of the core electronics parts, since they are common to most drones, but have the bodies designed according to specific requirements for each mission. A prototype drone was designed by engineers on shore based on requirements of the sailors at sea, and the 3D design file was emailed to the USS Essex over a satellite link. Flight tests revealed some of the potential problems, most of which were associated with operating the drone rather than the printing itself, Jaeger said. 'Even with a small amount of wind, something this small will get buffeted around,' he said. They also had to figure out the logistics of launching a drone from a ship, getting it back, how it integrated with other flight operations, and interference from other radio sources like radar.

66 comments

  1. Uncontrollable? by invictusvoyd · · Score: 0

    Flight tests revealed some of the potential problems, most of which were associated with operating the drone rather than the printing itself, Jaeger said. 'Even with a small amount of wind, something this small will get buffeted around,' he said. They also had to figure out the logistics of launching a drone from a ship, getting it back

    Shouldn't they be fixing this first?

    1. Re:Uncontrollable? by NatasRevol · · Score: 1

      Just needs more thrust & control surfaces.

      --
      There are two types of people in the world: Those who crave closure
    2. Re:Uncontrollable? by JaredOfEuropa · · Score: 4, Interesting

      No. This is innovation because they are using 3d printing (ohhh!); any problems of a practical or fundamental nature will be fixed at a later date. Maybe.

      I wonder: how many different drones for different missions would you really need? And can't they achieve the same by building a tested, stable, flyable drone platform, then adding attachments (3d printed or from stock) according to each mission's needs?

      --
      If construction was anything like programming, an incorrectly fitted lock would bring down the entire building...
    3. Re:Uncontrollable? by cdrudge · · Score: 1

      What's to fix?

      Too windy? A 3d printed drone won't be applicable for that mission, much the same way a Zodiac-based landing party wouldn't be suitable during a hurricane.

      Need to launch? Toss in air. It's launched.

      Need to land? Land. If it falls in the water, oh well. Your disposable drone is disposed of. It's not like these are $4m Predators being made. The military spends more on consumables to flush a toilet than what these cost to make.

    4. Re:Uncontrollable? by Drethon · · Score: 1

      Just needs more thrust & control surfaces.

      Yep, just make it bigger so it has more power and... why is our drone now too large to launch from the ship? The history of miniaturization :)

    5. Re:Uncontrollable? by ComputerGeek01 · · Score: 4, Insightful

      There is some practicality to be realised here. What if instead of carrying around ten prefab copies of every component that might get damaged during operation you just carried around a block of material and printed out what you needed for repair on an as needed basis? This would also reduce the amount of loss due to components being damaged, warped or what ever the hell else in transit. As a civilian I have not the slightest idea what cost savings this might provide, but as a taxpayer the the thought of the US Navy of all organizations saving money brings a smile to my face. I don't even care if every penny of that savings gets dumped back into the F-35, it's still a step in the right direction.

    6. Re:Uncontrollable? by NatasRevol · · Score: 1

      That was kind of my joke.

      They should just change the names of airplanes to drones, sheet metal bending to 3D printing, and be done with it.

      --
      There are two types of people in the world: Those who crave closure
    7. Re:Uncontrollable? by Nidi62 · · Score: 1

      What's to fix?

      Too windy? A 3d printed drone won't be applicable for that mission, much the same way a Zodiac-based landing party wouldn't be suitable during a hurricane.

      Need to launch? Toss in air. It's launched.

      Go old school. Take what is essentially an old K-gun depth charge launcher and add a container for the drone that breaks apart at a certain height. This would allow the drone to get far enough away from the wind for controlled flight and doesn't waste power on the drone by having to take off in all the wind.

      --
      The only thing necessary for evil to triumph is for it to be pitted against a slightly greater evil
    8. Re:Uncontrollable? by RabidReindeer · · Score: 1

      Just needs more thrust & control surfaces.

      Yep, just make it bigger so it has more power and... why is our drone now too large to launch from the ship? The history of miniaturization :)

      Well, I guess you'll have to 3D print a bigger ship, then!

    9. Re:Uncontrollable? by RabidReindeer · · Score: 1

      Careful. How are the no-bid contractors going to charge big $$$ for mil-spec parts if you can just 3D print them?

      Sounds like a commie plot to me.

    10. Re:Uncontrollable? by ColdWetDog · · Score: 1

      Because when you have the preformed parts, you just go over and snap them together. When you have to print the parts, you warm up the printer, download the files, print the parts, fiddle with the printer, print the parts again and snap them together.

      Perhaps as an R&D setup, this makes sense - if you are trying to develop different frames / gizmos / attachments to the UAVs to fit various mission requirements. In a shooting war, not so much.

      "Sailor, we want an attack drone."
      "But sir, if I just adjust this part some more we can make it go faster"
      "Sailor, print out the goddamned drone."
      "But sir, I can make it so it has LED lights!"

      --
      Faster! Faster! Faster would be better!
    11. Re:Uncontrollable? by ColdWetDog · · Score: 1

      There is lots of money to be made in building (and supporting) mil-spec printers. And mil-spec plastic. And mil-spec designs.

      --
      Faster! Faster! Faster would be better!
    12. Re:Uncontrollable? by Anonymous Coward · · Score: 0

      The limitation with 3D printing everything is that it kind of walks away from hundreds of years of materials processing experience. You can't get forged parts, you probably won't get thermally processed parts (hardened, annealed, aged, etc), you probably won't be plating parts out there either, and you probably won't be cryo treating, nor plasma spray coating, etc. Everything is sort of dead soft. Sure, there's a lot of stuff that you can do with it, but there's more stuff that you still can't.

    13. Re:Uncontrollable? by Drethon · · Score: 1

      Just needs more thrust & control surfaces.

      Yep, just make it bigger so it has more power and... why is our drone now too large to launch from the ship? The history of miniaturization :)

      Well, I guess you'll have to 3D print a bigger ship, then!

      And then bigger people so everything remains to scale?

    14. Re:Uncontrollable? by Anonymous Coward · · Score: 0

      Easy. Charge even more $$$ for mil-spec printers and print media and service contracts for the printers.

    15. Re:Uncontrollable? by LifesABeach · · Score: 1

      Next step is a Captain's Mass. I hear they can be very linear.

    16. Re:Uncontrollable? by ceoyoyo · · Score: 1

      Carriers have machine and wood shops where they fabricate lots of things, including needed parts for the carrier.

    17. Re:Uncontrollable? by Anonymous Coward · · Score: 0

      I think this is more for:

      "We need to send this oddly shaped parcel to a SEAL team get one of the blank drones out of storage and print a cargo pod for it that can hold the parcel."

    18. Re:Uncontrollable? by Anonymous Coward · · Score: 0

      US Navy of all organizations saving money brings a smile to my face. I don't even care if every penny of that savings gets dumped back into the F-35, it's still a step in the right direction.

      As long as it is in development it is just a money sink. It is when it actually comes to use that there are savings.
      Be careful what you wish for, I'm pretty sure the operating costs for a couple of more wars quite easily eats those savings.

    19. Re:Uncontrollable? by tehcyder · · Score: 1

      mil-spec plastic

      "Yes, we know it costs 20 times as much, but it's in officially approved camouflage colours."

      --
      To have a right to do a thing is not at all the same as to be right in doing it
    20. Re:Uncontrollable? by KGIII · · Score: 1

      Do you mean "mast" perhaps? The chaplain may give the captain a private ceremony but it is unlikely, really.

      --
      "So long and thanks for all the fish."
    21. Re:Uncontrollable? by KGIII · · Score: 1

      All things considered, the Navy is actually pretty thrifty. They seem expensive because they have big-budget items but when you realize how large they are and what we pay for the items, they are not really that expensive. They, and by extension the Marines (a division of the Navy) generally get pretty good marks with GAO. They may spend a half billion on a carrier but that thing will be in service for 30 years and then mothballed and able to be brought back into service for another 50 years and will only need some small overhaul and electronics upgrades.

      All-in-all, if you look at it, they are not really all that expensive considering that they police the waters of the entire planet for pretty much every country without charge. We can all agree that the US should not be the world's police but that is a matter of debate - we are damned if we do and damned if we do not. I would submit that the USN is actually about the only area where we should be policing the world if we are going to do it at all. We do a very good job at it and are really quite respected for it. If you have never seen the event of a carrier group steaming into a foreign port then you are missing out.

      As a young Marine (Yay! GI Bill!) I got to guard the USS Kennedy for a little over six months. I went to Big John's decommissioning in '07 by the way. Anyhow, the amount of respect given and the happiness (and curiosity) is surprising. This trend continues today. You can watch any number of documentaries and shows that will give further information.

      As a huge fan of cutting back military spending this is one area where I think we have managed to achieve some sort of balance. We pay a lot, do not get me wrong, but we could be paying far more and getting fewer positive results. When Big John comes rolling into town, even in a European country with a lot of disdain for the US, there is an immense gushing of praise and thanks. Unless you have witnessed it then I really can not expect you to truly understand it. It has its effect everywhere. If you are a sailor or a Marine you *will* walk proud with your head high, arms back, and chest out in pride and rightfully so.

      I have shined me some brass and scrubbed a lot of stainless. There is not much guarding to do but tradition is tradition.

      --
      "So long and thanks for all the fish."
  2. 3D Printing? Drones? by Anonymous Coward · · Score: 0

    Are they IoT compatible? And are they connected to the Cloud and webscale? If they were it would be a 100% perfect activity as it hits all the buzzwords of the week!

    1. Re:3D Printing? Drones? by invictusvoyd · · Score: 1

      If they were it would be a 100% perfect activity as it hits all the buzzwords of the week!

      You mean the buzzwords of last week right?

  3. Seems silly. by AndyKron · · Score: 2

    That seems a little silly to me. Should I custom make the drone with four propellers, or four? Should I have a camera, or a camera? Should I have the most appropriate battery, or the most appropriate one?

    1. Re:Seems silly. by boa · · Score: 1

      That seems a little silly to me. Should I custom make the drone with four propellers, or four? Should I have a camera, or a camera? Should I have the most appropriate battery, or the most appropriate one?

      The cool thing isn't the number of propellers, but that they can change the model and produce a new drone on board. The alternative is to either get it delivered somehow, or return to a port to pick up the new drone.

      3D printing will save them lots of time if they choose to change the design. Also, spare parts can be produced on board the ship.

    2. Re:Seems silly. by Anonymous Coward · · Score: 0

      " The alternative is to either get it delivered somehow, or return to a port to pick up the new drone."

      " Also, spare parts can be produced on board the ship."

      Somehow I doubt that either of those statements has much bearing on reality.

      The expensive avionics and cameras will not be 3D printed, they will be kept in stock just like drones would be. They can either keep printing more drones, or they can just keep extra drones. It might be a nice space-saving move but it's not going to get them out of needing supplies to make more drones. It's not literally a star trek replicator.

    3. Re:Seems silly. by Captain+Hook · · Score: 4, Insightful

      I seems to me the real saving here is that powdered plastic is a lot denser than hollow aerodynamic plastic shapes and so won't take up anywhere near as much storage space.

      Rather than trying to store 1000 small drones on board, you just have a big tank with enough powdered plastic to make 1000 small drones and the various non-printable bits (electronics, batteries and motors), which are smaller and easier to store anyway

      Then you just keep 10-20 drones ready and print more off as you use up the stock of ready made drones.

      --
      These comments are my personal opinions and do not necessarily reflect the opinions of the other voices in my head.
    4. Re:Seems silly. by tomhath · · Score: 1

      It's not clear what they mean by "custom" though. The motors, batteries, and electronics are stock items. I don't see what custom features they can add; the "prototype" looks like only the plastic arms were printed.

    5. Re:Seems silly. by ArcadeMan · · Score: 1

      The alternative is to either get it delivered somehow, or return to a port to pick up the new drone.

      Can't the damn things, I dunno... delivery themselves?

      There's a manned solar airplane doing a trip around the world right now, why can't "tiny' drones also use solar panels?

    6. Re:Seems silly. by NatasRevol · · Score: 1

      Bigger propellers, longer wings/stabilizers just to name a few off the top of my head.

      --
      There are two types of people in the world: Those who crave closure
    7. Re:Seems silly. by NatasRevol · · Score: 1

      You realize that an aircraft carrier could outrun the solar airplane, right?

      And that military sometimes need some things quicker than 5-7 days?

      --
      There are two types of people in the world: Those who crave closure
    8. Re:Seems silly. by demachina · · Score: 1

      The cooler thing would be if you have enough high speed printing capacity that you could manufacture and assemble a 1000 drone swarm in a very short period of time and overwhelm an adversaries defenses without requiring a ship big enough to carry a 1000 completed drones. And then another one, and another one. You would need a tanker full of plastic and a freighter full of batteries, electronics and propellers.

      âoeKill decisionâ baby.

      --
      @de_machina
    9. Re:Seems silly. by thinkwaitfast · · Score: 1

      They should check out http://flitetest.com/. These guys pop out new drones in minutes with no need for for a 3d printer.

    10. Re:Seems silly. by Anonymous Coward · · Score: 0

      Ironically, if they were printing fixed-wing drones, a 3d printer would actually be useful because the drone's characteristics would actually be altered meaningfully by changing what you print out. With one avionics system capable of controlling multiple motors, one type of speed controller, one type of motor, maybe two types of props and a modular battery system, you could print drones, add a very small set of basic unprintable parts, and be able to manufacture drones with a wide range of capabilities.

      For a quadcopter the airframe is basically "Is it strong enough" and "is it too heavy". Aside from trivial shit like accessory mounts there is really no difference between a 3d printed quadcopter airframe or an aluminium one or a composite one.

    11. Re:Seems silly. by RespekMyAthorati · · Score: 1

      Duh! Use prime.

  4. This just in by DNS-and-BIND · · Score: 4, Interesting

    Newsflash: places with machine shops need to fabricate objects, so they use the latest technology available. Surprise to uneducated people: US Navy ships have machine shops on-board, because they often need to fabricate objects while at sea. The surprising twist: when you're at sea, you can't just order from Amazon, you have to make it right then and there. Crazy, eh?

    --
    Shutting down free speech with violence isn't fighting fascism. It IS fascism!
    1. Re:This just in by Anonymous Coward · · Score: 0

      Darn. You said it before I could.

    2. Re:This just in by ArcadeMan · · Score: 1

      The machine shop part I understand, but do they store raw materials or do they also have a foundry onboard? :p

    3. Re:This just in by RabidReindeer · · Score: 1

      The surprising twist: when you're at sea, you can't just order from Amazon, you have to make it right then and there.

      But what about Amazon's drone delivery service?

    4. Re:This just in by DerekLyons · · Score: 2

      US Navy ships have machine shops on-board, because they often need to fabricate objects while at sea.

      Other than carriers and large support vessels however, the machine shops are generally pretty basic and operated by relatively unskilled/inexperienced people. (They're trained in the operation of the tools, but it's not their full time job.)

      3D printing is a game changer even for the Navy in that it requires essentially no skill or significant training.

    5. Re:This just in by ColdWetDog · · Score: 2

      Look, here are some pictures of an older carrier's machine shop. No, you won't find this on a small cruiser - but you also don't find the poor little cruiser out in the middle of the ocean by itself. So if gizmo A breaks on the little boat, the big boat's machine shop can likely fix it.

      Having some 3D printers isn't going to materially change things. It will change things a little - those pictures are from a post WW 2 carrier, I imagine newer boats have full on CNC machines. And I imagine that, sooner or later, there will be 3D printers. But they won't be game changers, they will simply be evolutionary changes.

      3D printers are NOT generic replacement devices. They can only make a narrow range of 'things'. A decent CNC mill is quite a bit more versatile, even if you have to go to school to learn how to use it.

      --
      Faster! Faster! Faster would be better!
    6. Re:This just in by JazzLad · · Score: 1

      Yo, dawg, I herd you liked drones so I delivered you a drone with a drone.

      Did I do that right?

      --
      "If you have nothing to hide, you have nothing to fear." - Every fascist, ever
  5. Logical next step. by Anonymous Coward · · Score: 0

    We need to be able to 3D print drones that can 3D print more drones. This is the answer to scaling up quickly and overwhelming the enemy. Bonus if you can incorporate human brains or body parts into the mix.

    1. Re:Logical next step. by ArcadeMan · · Score: 1

      So... are you talking about The Borgs? The Cybermen? Something else?

  6. Here we go again... by ArcadeMan · · Score: 1

    Do you want Skynet drones factories?

    Because that's how you get Skynet drones factories.

    Seriously, all the parts seem to be falling into place. Time for a reboot of the Terminator franchise? (one without humanoid robots walking around and delivering punchlines).

  7. Why are they printing this? by Karmashock · · Score: 1

    Print what you actually need on board ship... repair parts... These ships have big inventories of parts that they know will wear out, parts that could break, and of course... consumable munitions.

    These are the things you print aboard ship.

    Rather than giving a ship a huge inventory of repair parts, you give them a few printers and the raw materials to print whatever is needed.

    This can't work with everything... at least with our current level of technology. But the idea should be to give the Navy more space in the cargo hold for things besides repair parts because they can make them as needed. Or to give them the ability to fabricate things faster than they can be transported to them.

    If the printers aren't doing either of these things then they're just taking up space.

    These are supposed to be war ships. Its not fing star trek with a little science team on board. They're engines of destruction. Everything has to service that end aboard ship. If you have another agenda... get your own boat and do it there.

    --
    I've decided to stop wasting my time responding to AC trolls/sockpuppets... so if you want a response from me... login.
    1. Re:Why are they printing this? by Anonymous Coward · · Score: 0

      I wonder if they can 3D print in semtex?
      The drone IS the weapon.

  8. Define "drone" by leftover · · Score: 1

    Not to be tedious but those are just r/c quadcopters. Many people print them on hobby-class 3D printers.

    Printing a customized Predator would be a worthy goal, calling this effort "research" is just pathetic.

    --
    Bent, folded, spindled, and mutilated.
    1. Re:Define "drone" by thinkwaitfast · · Score: 1

      Some people make them out of sticks and superglue.

  9. Sweet by Translation+Error · · Score: 1

    We're going to be the Protoss!

    --
    When someone says, "Any fool can see ..." they're usually exactly right.
  10. Took years for the V-22 Osprey to work right by Zeorge · · Score: 1

    On a ship you have more than cross winds, you have wind coming up the sides and the acceleration across the deck, etc. I don't think a battery powered drone, even with enough control surfaces and mass, would have much flight time.

    1. Re:Took years for the V-22 Osprey to work right by Anonymous Coward · · Score: 0

      I play with quadcopters a lot. Even in 20 km/h wind, a high performance one (meaning not a Phantom or something) with no useful features like camera gimbals, etc, will have its battery life at least cut in half, down from ~15 minutes to 5-7 minutes.

      However, if they used fixed wing drones, the high airspeeds would not matter as much. Recovery could be achieved by hanging a net off the side of the ship and flying the drone right into the net. Obviously this only works for modest size drones, as there is a nonzero probability of flying it right into your ship, but a 5 lb model aircraft going 50 km/h shouldn't really pose a threat to a destroyer.

  11. A solution in search of a problem by OneSmartFellow · · Score: 1

    Enough said

  12. That design looks familiar by Anonymous Coward · · Score: 0

    I'm pretty sure they just printed out this quad from thingiverse. http://www.thingiverse.com/thing:234867

  13. They have raw material on board by Zeorge · · Score: 1

    The machine shop had rods and sheets of various metals. The typical assortment of machines as well.

  14. I agree by Zeorge · · Score: 1

    I discussed with some others before in that printing on a ship or forward deployed base is a waste of money, time, and space. I could see the various depots having printing shops, that makes sense. That'd certainly save on local inventory. Another factor is MILSPEC, they'd have to MILSPEC it all again for 3D printed parts. Not too hard but expensive an time consuming.

    1. Re:I agree by Karmashock · · Score: 1

      Well, that assumes the ships aren't given a proper 3d printer that can print the literal parts you need to milspec. We have printers that can pump out parts of the aerospace industry so they can print parts for your ship.

      BUT you need that level of printer. And then you need to do a cost/weight evaluation to make sure you're actually making a good trade.

      Only on the largest ships am I guessing this might make sense.

      But think of it... a major issue for the ships is having all the repair parts for all the planes AND the ship and various other things.

      What if you could print out a lot of the parts from some feedstock material. Print the part out of titanium or whatever works for you.

      --
      I've decided to stop wasting my time responding to AC trolls/sockpuppets... so if you want a response from me... login.
  15. Sounds like by Sheik+Yerbouti · · Score: 1

    A faculty research associate wanted to play with 3D printers and drones on the federal dime.

    1. Re:Sounds like by ColdWetDog · · Score: 1

      And get an all expense paid cruise!

      What's not to like? Besides the food, the entertainment, the rather spartan accommodations, the saluting ....

      --
      Faster! Faster! Faster would be better!
  16. US, 3D printing, drones by WallyL · · Score: 1

    Bingo!

  17. You have no idea what you're talking about. by DerekLyons · · Score: 1

    No, you won't find this on a small cruiser - but you also don't find the poor little cruiser out in the middle of the ocean by itself.

    Actually, yes, you do. The Navy does a lot more than just sail around in full carrier centric battle groups.

    I imagine newer boats have full on CNC machines.

    They don't.

  18. In AMERICA one thing we don't lack is BIG PEOPLE!

  19. yes, they do have a foundry by Anonymous Coward · · Score: 0

    http://www.amazon.com/Foundry-Manual-United-States-Navy/dp/1410109003/ref=sr_1_1?ie=UTF8&qid=1438292069&sr=8-1&keywords=us+navy+foundry+manual

    you can't carry spares for everything

  20. duh by Anonymous Coward · · Score: 0

    Some people here seem pretty stupid.

    Obviously as a new tech the Navy and other Services as going to investigate new tech and see where it fits into their repair chain.
    Just like they did 10 years or more ago with railguns, they will investigate, research, and improve upon the current state of the art.

    5-6 years from now, it might be commonplace for them to be able to replace almost anything plastic or metal from some sort of 3D printer/CNC mashup. As said, Avionics is doing it, so doing it on a floating ship shouldn't be too hard, unless its in the middle of a pitched battle.

  21. Space missions by l0n3s0m3phr34k · · Score: 1

    This is along the lines of my idea for modular space exploration probes...I put a brief abstract here on my site. The basic idea is a space-based 3-d printer that also brings along the unprintable probe parts and electronics, and can print out the body of the probes per mission criteria. Also, the electronic packages are in a modular system so we can send out "refuels" of unprintable parts on regular basis so the system can keep on exploring with minimal human interaction for many years.