During the transit to RIMPAC 2026, a containerized xCell factory aboard the USS Essex produced twelve Squall drones and more than 1,000 parts. It was the first maritime run of Firestorm Labs' platform, and printing continued in waves of up to 12 ft. The output included spare parts for Apache helicopters.
Key facts
Two expandable 20-foot containers hold printers and assembly stations
Twelve Squall drones and over 1,000 parts printed during the RIMPAC 2026 transit
Production continued in waves of up to 12 ft
Context HP Multi Jet Fusion is a powder bed polymer process that fuses nylon powder layer by layer with a fusing agent and heat.
What did the xCell factory do on board?
The system fits in two expandable 20-foot ISO containers, or one 40-foot equivalent. It combines industrial HP Multi Jet Fusion printers with semi-automated assembly stations. Over roughly two weeks of transit, it made twelve flight-ready Squall quadcopters and more than 1,000 parts. Rough seas with waves up to 12 ft did not stop production.
Which parts were made?
Squall is an NDAA-compliant FPV drone with up to 20 miles range, 42 minutes flight time and a 5.5-pound payload. After arrival, the drones were used in a counter-drone exercise in the role of opposing aircraft. Other parts included Apache rotor droop-stops, a vacuum-hose coupling for life preserver testing, covers for electrical fittings, a Starlink bracket and gauges for deck tie-downs.
What it means
The result shows that polymer powder bed printing can run in a shipboard environment, mainly for spares and low-risk fittings. For European manufacturers, the lesson is the model: a compact, containerized cell close to the point of need. Qualification of printed flight and aircraft parts, and the skills to run such a cell, remain the open questions.
Frequently asked questions
What is xCell?
xCell is Firestorm Labs' containerized expeditionary manufacturing platform with HP Multi Jet Fusion printers and semi-automated assembly stations.
What did the USS Essex print?
Twelve Squall FPV drones and more than 1,000 parts, including Apache rotor droop-stops and a Starlink mounting bracket.