Small Unmanned Aerial Systems Production by the Millions

Abstract

The United States small unmanned aerial systems (sUAS) industrial base faces vulnerabilities due to heavy dependence on Chinese components and limited domestic manufacturing capacity relative to near-peer competitors. Future conflicts demand rapid drone production at scale; the U.S. must identify optimal platform investments and develop mass production capabilities that meet operational tempo requirements. Ukraine’s transformation from defensive to offensive drone operations demonstrates the strategic importance of domestic manufacturing—Ukrainian forces have maintained supply continuity by producing drones locally rather than relying on imported completed platforms. This research uses qualitative and analytical methods, including interviews, onsite observations, and analysis of relevant publications. The research examines the composition and supply chain origins of current Blue sUAS platforms to provide leaders with insights to strengthen U.S. drone manufacturing capabilities. Understanding these component dependencies is essential for developing a resilient sUAS industrial base capable of supporting future military operations. Throughout the research, it is apparent that key critical components could prove a detrimental impediment due to geographical dependencies while operating in a contested environment. Ultimately, research recommendations point to the need to incentivize the industry to ensure preventive measures that allow the DoD to begin building a drone stockpile.