The Army Modernization Strategy outlines how the Service will become a multidomain force capable of operating across land, sea, air, space, and cyber domains by 2035. As part of the strategy to deliver a force capable of multidomain operations, the strategy outlines six critical modernization efforts: long-range precision fires, next-generation combat vehicles, future vertical-lift aircraft, air and missile defense, advanced communication networks, and individual Soldier lethality. Prioritizing next-generation munitions has become central to the modernization strategy to ensure land-power superiority. Upgrading major munitions systems such as missiles is essential, but modernization should also address supporting technologies, none more prevalent than drones and the munitions they carry.
Drone Technology
In addition to prioritizing core modernization efforts, the Army is pursuing complementary initiatives. Informed by ongoing conflicts, drone technology and next-generation munitions have emerged as crucial elements. One upcoming category, drone munitions, is revolutionizing modern warfare. Small, unmanned aerial vehicles (UAVs) can carry a variety of explosive payloads, allowing for precise strikes on enemy positions with minimal risk to frontline forces. The drones usually fall into Group 1 (less than 20 pounds). For larger munitions, Group 2 drones (between 21 and 55 pounds) may need to be used.
The most advanced drones are first-person-view (FPV) drones, which offer a new take on drones and bring a new level of threat, unlike traditional remote-controlled drones, where the pilot uses a bird’s-eye view on a screen. An FPV drone is equipped with a camera mounted on the front, transmitting a live video feed to a headset or goggles worn by the pilot. Drones have proved they offer greater flexibility and affordability than traditional airstrikes, operating at lower altitudes and reaching previously inaccessible areas. Though the Army’s drone and counter-drone capabilities are a growing priority, senior leaders have rejected calls for a separate drone branch, deeming it counterproductive.
Regardless of the future of drone capabilities, modernization of munitions for drones is a must, particularly the development of drone-dropped and loitering munitions, which are likely to be key elements of future warfare. Ongoing advancements drive this focus on drone-delivered weaponry, such as loitering munitions. While both loitering munitions and drone-dropped munitions deliver explosive payloads from UAVs, they serve distinct purposes. Loitering munitions, armed drones that wait in target areas before crashing into their objective, offer faster response times, potentially lower civilian harm, and reduced manned aircraft risk. Subsets of this category are the munitions-strapped drones that can take on the role of traditional loitering munitions. Drone-dropped munitions are distinct. They are explosives delivered (dropped) by UAVs while offering advantages like precise targeting, reduced risk to pilots, and the potential for faster response times.
The choice between these options depends on the mission’s needs and the target’s value. The Army’s launched-effects program is a separate initiative based on three ranges: the ongoing medium-range option, short range, and long range. These are essentially small drones launched by a larger vehicle mid-flight and can be used for intelligence, surveillance, and reconnaissance or for kinetic effects to strike targets.
Modernization Approaches
When it comes to drone-dropped munitions, three main approaches exist for the short term: leveraging existing munitions (grenades, mortars, mines) for drone-dropping operations or strapped to drones for direct-attack loitering operations, using 3D-printed assembled cases (drone-specific munitions), and using improvised explosive devices (IEDs) such as soda can bombs and Molotov cocktails. The last approach would be to create a new class of drone munitions. Immediate modernization efforts should be directed at the first option, which offers a faster and more economical route. Adapting current munitions designs, reducing development costs, using existing supply chains, and familiarizing military units with them can quickly integrate them with drones.
However, relying solely on existing munitions for drone deployment creates a potential conflict with the evolving requirements of modern warfare. Legacy weapons, designed for traditional applications, may not fully address the needs of a rapidly developing drone ecosystem. Modernization efforts demand munitions that can keep pace with advancements in drone technology, flight range, and payload capacity, which additive manufacturing and 3D printing can offer.
For long-term modernization, the Joint Program Executive Office Armaments & Ammunition would have to manage the development of new drone munitions. This would include funding and overseeing research and development, since the organization would work with other Services, commercial partners, and research institutions to fund projects focused on innovative drone ammunition concepts. Research projects would include new materials, propellants, fuses, and delivery mechanisms for drone-specific munitions. In time, acquisition and testing would require the evaluation of proposals for new ammunition types.
Additionally, the new ammunition types would require extensive testing, and the acquisitions process would have to be managed to ensure munitions were ready for military use. This would include integrating and fielding the new class of ammunition until it were proven and rigorously validated to standards that would also need to be developed. Lastly, the deployment to military organizations and the sustainment phase would have to include new equipment training, storage, and logistics for the new munitions. While drone munitions must go through the entire DoD acquisition process, we can take lessons from other nations for modernization efforts.
Drone Munitions
Ukraine created special ammunition for drones and has officially set up a separate category, while Russian industry also started the production of drone ammunition. Both countries are already adapting their current inventory of munitions for drone-dropping from commercial drones. Despite the increased use in the last few years, drone-dropped munitions have lacked a unified standard. Military munitions have been adapted for drone deployment, such as grenades or mortar shells being modified for dropping. However, at the Black Sea Defense & Aerospace exhibition held in Bucharest, Romania, in May 2024, Carfil S.A., a subsidiary of Romania’s state-owned defense company ROMARM, unveiled a new family of drone-dropped munitions. These munitions leverage ROMARM’s existing range of mortar bombs in various calibers, including 60 mm, 81 mm, 82 mm, and 120 mm. Carfil S.A.’s approach represents a standardization for a national defense firm integrating drone technology into military units.
There are many benefits of a standardized approach, including a reduction of development costs by using proven munitions designs and eliminating the need for new drone-specific munitions. Military units familiar with the munitions can seamlessly integrate them into drone operations, minimizing training and ensuring compatibility with existing stockpiles. Military branches or allied forces using similar drones can share and use compatible drone-dropped munitions or attached munitions, enhancing operational flexibility and effectiveness. Carfil S.A.’s approach is a blueprint for other defense firms aiming to embrace drone technology. They can streamline development, logistics, and interoperability by prioritizing standardization, leading to a more agile and responsive military force.
Modernization in 3D-printed munitions cases offers greater customization. These cases can be tailored for drones, optimizing weight and overall performance. 3D printing also holds the potential for cost savings on complex designs compared to traditional manufacturing methods. Additionally, it allows for rapid prototyping, facilitating faster design iteration and testing cycles. However, this approach comes with design standardization, approval, and production challenges.
One Ukrainian company that has overcome many of these hurdles is Stalevi Shershni, which translates to Steel Hornets in English. The company sells drone bodies in Ukraine. All ammunition is delivered as assembled cases but without explosives and detonators. A critical area for development in the DoD’s additive manufacturing strategy lies in 3D-printed drone munitions cases. This technology holds immense potential for increasing a military unit’s flexibility. On-demand production of lightweight, custom-designed cases tailored to specific missions could optimize aerodynamics and specialized battlefield scenarios. While 3D-printed cases offer customization and lighter weight for drone-dropped munitions, this approach requires meticulous design and high-quality materials to ensure safe and reliable detonation. 3D printing introduces uncertainties in strength and consistency, potentially leading to malfunctions or catastrophic accidents.
Lastly, IEDs strapped onto drones have become a growing concern in warfare and have played a significant role in irregular warfare. These weaponized drones offer insurgents and non-state actors a cheap and accessible way to inflict damage and casualties. The ease of attaching IEDs to commercially available drones lowers the technical barrier to their use. The small size and ability to evade traditional air defenses make them challenging to detect and counter. These types of attacks pose significant threats to military personnel and civilian infrastructure, particularly in strategic support areas where collateral damage from explosions can be devastating. The use of IED-laden drones in conventional warfare demonstrates the increasing adoption of irregular tactics as the nature of conflict evolves and as munitions supplies have dwindled. To optimize modernization efforts, the Army should integrate lessons from irregular warfare directly into new tactics, techniques, and procedures development, instead of treating them as a distinct modernization effort.
Conclusion
Modernizing drone-specific munitions requires a strategic balance. Factors like drone capabilities, mission specifics, budgetary priority, and munitions production influence the optimal approach. Adapting existing munitions offers a quicker and more economical path for initial integration, allowing for rapid deployment. However, these munitions might not fully address future needs. 3D-printed cases, while demanding more significant investment in development and logistics, hold immense promise for specialized, potentially lighter munitions. The future of warfare undeniably revolves around drone technology, and the Army must ensure its munitions modernization keeps pace. This necessitates a multifaceted approach: leveraging existing options for initial fielding while investing in 3D-printed solutions to maintain a decisive edge over near-peer competitors in large-scale combat operations and over non-state actors in irregular warfare. As drone munitions become increasingly crucial, the future could see not only a dedicated project office but also the emergence of a distinct category of munitions designed explicitly for drone deployment.
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Chief Warrant Officer 4 Michael K. Lima currently serves as the training developer with the Ordnance Training Development Division. He is assigned to Headquarters and Headquarters Company, 59th Ordnance Brigade, the Ordnance Corps and School under the Combined Arms Support Command at Fort Gregg-Adams, Virginia. He has participated in the Training with Industry program with a prime missile defense contractor and was an accountable officer for the Army ammunition supply point at Kadena Air Base in Okinawa, Japan. He holds a doctorate in business administration from Baker College.
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This article was published in the fall 2024 issue of Army Sustainment.
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