Attempting to build 10 million drones is an enormous undertaking, Jon Strzelec, U.S. Army Materiel Command’s advanced manufacturing lead for small uncrewed air systems, tells Aviation Week. “That’s five circuit cards per drone, so it’s 50 million circuit cards,” Strzelec says. “You’re talking four motors per drone—that’s 40 million motors, 40 million propellers, 10 million frames.”
Faced with those daunting numbers, the Pentagon has ordered a half-dozen army depots that are typically used for maintenance, repair and overhaul of aging military equipment to jump into the fray and start manufacturing drone components.
Depots are being retooled with additional manufacturing equipment to produce brushless DC motors, propellers, frames, circuit cards, battery packs and other drone subcomponents, Strzelec says.
For example, one facility that repaired out-of-production radios has been revamped to support electronics for uncrewed air vehicles (UAV). “If they can make and produce circuit cards for an Army radio or a radar, why couldn’t they do it for a system on a drone?” Strzelec notes.
Tobyhanna Army Depot in Pennsylvania opened a brushless DC motor assembly line this summer. The depot has the capacity to scale production to upward of 500,000 motors annually, the service says.
Strzelec declines to state production goals for the initiative, citing operational security concerns. The drone effort is part of a larger $18.1 billion modernization plan aimed at transforming the U.S. Army’s Organic Industrial Base, the service-owned complex of 23 depots, arsenals and ammunition plants.