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 automobile (UAV) Hellhound S3 is a kamikaze drone designed for long-range, precision strike missions towards armored automobiles, 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 elements authorized 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 underneath 25 kilos, together with the automobile, 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 yr. Final yr, Military management requested $120.6 million from US lawmakers for its LASSO initiative because the Pentagon seems to be to restock its munitions arsenal.
“The trendy 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 sooner–gathering intelligence and putting essential targets deep within the contested areas earlier than the enemy has time to react.”
3D printed loitering munitions improve Military warfighting
Designed to reduce collateral harm with exact payload supply, Hellhound 3 helps standard warheads, digital warfare, and intelligence, surveillance, and reconnaissance (ISR) payloads. Based on Cummings Aerospace, troopers can field-swap payloads with out instruments in underneath 5 minutes, enhancing mission flexibility. The system’s modular design will enable 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 had been licensed at Expertise Readiness Stage 7 (TRL-7), demonstrating their reliability in operationally practical situations.
Throughout three flight checks, the turbojet-powered munition surpassed 350 mph at half throttle, masking over 20 km whereas consuming simply 50% of its gasoline. Moreover, inert payload checks 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. Based on 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 checks 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 produce the whole loitering drone system to TRL 7. It additionally plans to conduct further demonstrations for different clients.
Additive manufacturing bolsters US protection capabilities
Cummings’ new kamikaze drone seeks to handle the DOD’s rising demand for airborne munitions because it strengthens home provide chains. The Pentagon elevated its annual funds 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 yr, rocket engine producer Ursa Main and Virginia-based Raytheon Applied sciences accomplished profitable US Arm flight checks for a long-range stable rocket motor (SRM). Ursa Main’s Lynx 3D printing know-how was used with Raytheon’s digital engineering capabilities to provide the SRM. Additive manufatcring has reportedly allowed the Colorado rocket engine maker to attain “unprecedented timelines,” with almost 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 subsequent 4-5 years. Whereas the corporate hasn’t confirmed the position 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.
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Featured picture reveals a Hellhound turbo-jet-powered loitering munition. Picture by way of Cummings Aerospace.