3D printed engines will change rocket and UAV manufacturing technology

The small size of 3D printed engines plays an important role in the development of missile technology. It allows complex components to be created at lower costs, reduces production time and restores design flexibility to meet the special requirements of defense needs.

In modern high-intensity warfare, a huge number of missiles and UAVs are needed that can be produced quickly and at low cost. This is inherently the weakness of many military powers that are famous for their "weapons technology strength".

To put it simply, in a conflict, the weaker side uses simple, cheap weapons to launch a massive attack on a much more technologically powerful opponent. The attacked side must use expensive anti-aircraft missiles that can cost millions of dollars just to shoot down a UAV or rocket that costs only a few hundred dollars.

For example, a Patriot missile costs up to $4 million. Meanwhile, a Tamir missile costs $100,000 - $200,000 each, while the Qassam missile made by Hamas costs only $500-600 each. This will create a terrible difference in consumption, overloading air defense systems, and creating difficult-to-balance financial pressure.

The same goes for UAVs, which have forever changed the way conflicts are fought. This has forced military powers to find solutions that can ensure the timely supply of weapons in huge quantities, but at a reasonable price. So this is where 3D printed engines come into play.

Small engine models, 12 to 20 cm in size, with thrust from 100 to 300 lbf and weighing about 6.8 to 16 kg, were produced very quickly by this method. Helping the militaries of countries quickly fill the gap in engine production capacity and ensure spare stocks.

These types of engines could be used for missiles, new lighter cruise missiles, or many drones. In the event of a conflict, especially a prolonged one, thousands of these engines would be needed.

In Ukraine, the country currently produces 5 million small drones a year and is aiming to produce around 300,000 long-range drones a year. Even the US cannot reach that level of production. This shows that all militaries in the world need to urgently restructure and soon put 3D printed engines into production for defense.

Unlike Russia, China or India, there are almost no companies producing commercial micro-turbines in the US. Recently, a name has emerged and this contractor has quickly received special attention from the Pentagon. That is Beehive Industries.

The company quickly won a $12 million engine printing contract for the US Air Force in October 2024, and in March 2025 managed rapid procurement projects for the Pentagon to further research propulsion systems for Unmanned Aerial Vehicles (UAVs) by developing the 200 lbf Frenzy engine.

Beehive Industries is sitting on a real gold mine if they can pull this off. They operate in a relatively new market with few reliable products. The company uses GE 3D printers with an experienced team (often former GE employees). With the many advantages that additive manufacturing brings in terms of weight reduction, better flow, part consolidation, reduced assembly, easier purchasing, etc.

The Beehive is just one example of the role 3D printing has played in manufacturing, particularly in the production of military rocket and UAV engines. It has changed an industry forever, by irreversibly changing the ways of modern warfare.