The U.S. Army introduced an experimental 3D-printed drone developed with direct input from frontline troops, aiming to create equipment aligned with real battlefield needs.
Researchers at the U.S. Army Combat Capabilities Development Command Army Research Laboratory (ARL) developed an experimental 3D-printed small unmanned aerial system (UAS), commonly known as a drone. It was demonstrated at the inaugural U.S. Army Best Drone Warfighter Competition in Huntsville, Ala.
The ARL team incorporated soldier feedback early in the design process for the Soldier Portable Autonomous Reconnaissance Transitioning Aircraft (SPARTA). They leveraged the lab’s research facilities for an easy-to-assemble drone designed to enhance intelligence, surveillance, and reconnaissance capabilities.
At the competition, ARL researchers served as subject matter experts and judges while showcasing SPARTA to senior commanders and soldiers. They also gathered feedback to refine the system and inform future drone designs.
Weighing about two pounds, SPARTA has an expected flight time of 30 to 60 minutes and a range exceeding 30 kilometers, depending on payload, while operating below 500 feet above ground level.
The drone features a large, open bay for electronic components, allowing soldiers to mount and swap parts quickly to meet mission-specific needs. Its airframe can be 3D-printed overnight and assembled without specialized tools or technical expertise.
Winning teams at the competition received a SPARTA prototype and a 1-year research-and-development agreement with the ARL to support further design improvements.
ARL also provided SPARTA to the 11th Airborne Division, where soldiers constructed, operated, and evaluated the drone in realistic scenarios, offering feedback to improve usability and performance.
According to officials, the effort supports the Army’s Transformation in Contact initiative, which seeks to accelerate delivery of new technologies to operational units.
Officials also said the research team plans to share the SPARTA model with additional units and continue engaging industry partners to move the technology toward large-scale production.
“We want to develop a soldier-centric design and feedback cycle,” said John Hrynuk, mechanical engineer at ARL. “We hope that we can eventually change how the Army procures drones to deliver new technology faster.”