The near future of defense is not going the way yesterday envisioned. A decade ago, the industry was trumpeting next-generation innovations such as advanced autonomous drones, smart armor and hypersonic weapons. Pundits were pounding the table on advanced technologies and materials in armored personnel vehicles, fighter jets, satellite-based defense applications and cyber warfare. Then Russia invaded Ukraine in early 2022 and the dynamics veered in a slightly different direction.
Unexpectedly, the world witnessed a reversion to almost World War I-style fighting tactics. Trench warfare. Low-cost munitions. Low-tech drones. A focus on causing the most amount of damage while spending the least amount of money in a war of attrition has been going on and on.
In the defense manufacturing sector, we have felt the ripple effect of the war in Ukraine through a renewed interest in producing 155 mm artillery shells, a form of ammunition that originated in the 1800s. The 155 mm has gone from a projectile primarily used for training to the backbone of NATO’s artillery strategy.
The U.S. has already shipped more than 3,000,000 rounds of 155 mm shells to Kyiv, and its stockpiles are thinning. This is why the agreement reached between Macrodyne USA Inc. and UNION to launch the “Factory of the Future” in Texas for two identical, fully automated lines to manufacture 155 mm shells was such a significant milestone. Production is expected to begin by the end of this year, with the second line ramping up in 2026. This initiative will help rebuild critical stockpiles to their former levels.
The Drive for 5%
Earlier this year, in response to growing concerns over countries like Russia and China, NATO allies agreed to boost defense spending to 5% of GDP. This represents a major increase from the previous 2% GDP target, and an unprecedented commitment that will reshape military spending priorities throughout NATO member countries. However, these nations have promised to spend their increased budgets wisely. The trend we’re seeing in Ukraine, the idea of implementing the most cost-effective solutions, is expected to continue. How will these increased resources be allocated?
“One of the changes we’re seeing is the approach to drone deployment,” offers Alex Edge, Senior Business Development Manager – Global Markets – Macrodyne and DUNKES. “In Iraq and Afghanistan, the drones deployed like the MQ-9 Reaper drone could be controlled by operators very much at arm’s length in another country. Now we’re seeing operators much closer to the battlefront controlling much smaller drones.
“We’ve gone from state-of-the-art drones valued at $10 million or more to drones that only cost $1,000 each but swarm in high numbers, can cause tens of thousands, if not hundreds of thousands worth of damage, and are valued so little in terms of investment that they don’t need to come back. This development, in turn, has led to increased investment in anti-drone warfare. That’s where we’re seeing a lot of the new spending.”
One aspect of defense manufacturing that is being completely reimagined is the way contracts are being handed out. Until recently, contracts were awarded to a handful of specialized firms that managed every facet of the project in-house. This paradigm has changed, and nations are now much more willing to work with new players that specialize in one facet of a defense manufacturing endeavor and onboard them quickly. This evolution is allowing innovation to flow faster.
“As a new entrant, you don’t have any of the fetters that traditionally bind you to a particular process or way of thinking,” elaborates Alex. “Let’s say you want to make a drone. You start bidding for parts, maybe propeller blades for 60¢ each that can lift a 1 kg drone. You put that bid out to the market and companies are going to respond and bid against each other to win that work.
“Suddenly, instead of making hundreds of these drones, you can make thousands, maybe with a slightly different material that works just as well at propelling the drone, but at a lower cost. That’s where the innovation is going to come from.”
Harnessing Automation to Boost Production
Another way defense manufacturers can ramp up volume without sacrificing quality and safety is to look at the latest automation solutions. With automation, manufacturers can go from handmade long fiber composites to short fiber composites, which brings the cost-per-unit down by a factor of five while achieving a higher build rate. And while the automation tools might cost more up front, if the project is expected to run for 10 years, companies can amortize that cost over the project’s lifespan and thousands upon thousands of parts.
“The better the process, the better the part,” adds Timo Kollmann, CEO of DUNKES. “Automation provides an airtight, dependable process. With a better process, you can produce parts faster, cheaper and more reliably at scale. Between today’s heightened security concerns, increased budgets and the prevailing military strategy to use more equipment to do more damage, automation is the key way to meet demand. It’s very much worth the investment.”
What other emerging trends in defense manufacturing are on the horizon? Contact us to arrange a consultation session with a Macrodyne defense manufacturing expert. You can also visit the Defense Presses page on Macrodyne’s website to learn more.
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