The US Department of War (DoW) has named Machina Labs to develop and qualify a RoboCrafted metal airframe for a new low-cost uncrewed combat attack system (LUCAS)-class uncrewed aircraft.
As part of the programme, Machina will also deploy two pilot expeditionary robotic manufacturing sites, known as Edge Factories, to support production closer to operational needs.
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Described by the company as its largest single award to date, the project is intended to modernise unmanned aerospace manufacturing and respond to increasing requirements for low-cost air systems that can be rapidly produced and adapted for changing operational missions.
Machina Bellator, the dedicated defence subsidiary, will lead the programme, beginning with development and qualification at its Los Angeles facilities.
Following the initial development phase, Machina intends to stand up two Edge Factories, which are containerised, rapidly deployable production sites based on the company’s RoboForming technology.
These facilities are designed to manufacture metal airframes from digital geometry without the need for traditional dies or hard tooling and require minimal site preparation.
Each site will be equipped with a containerised RoboCraftsman manufacturing cell, Machina’s proprietary software, forward-deployed personnel, and complementary production equipment.
Machina stated that its approach is based on a Modular Open Systems Architecture, enabling production of a family of mission-specific drone designs from a single manufacturing cell.
The company said this allows for airframes to be built in a fraction of the time and cost typically associated with composite manufacturing, removing the need for centralised, tool-heavy operations.
Machina founder and chief executive Ed Mehr said: “Producing low-cost systems at scale requires a manufacturing model that can move as quickly as mission requirements change.
“This programme brings our ‘build anything, anywhere’ mission to life by connecting adaptable UAS design with flexible production capacity closer to the point of need.”
The planned manufacturing process utilises a workflow developed in collaboration with nTop, incorporating parametric design, automated engineering analysis, robotic forming, and final assembly.
By using nTop’s engineering platform, Machina is able to create and adapt parametric airframe models and conduct rapid computational analysis on multiple design variants.
Updated designs can reportedly move from digital model to manufactured airframe within days, in contrast to traditional manufacturing cycles that may require new tooling and extended lead times.
Machina reported having already demonstrated the approach by creating and flying a UAS demonstrator, completing the assembled structure just weeks after the final design was approved.
The DoW’s Organic Industrial Base Modernisation Challenge seeks to update and improve defence manufacturing infrastructure and processes to better support emerging defence requirements.
Machina did not disclose the contract’s value, while Bloomberg reported that it was worth $9m.
The company described the award as pivotal to advancing its deployment of modular, rapidly adaptable manufacturing capabilities for military applications.
