3D Printed Loitering Drone Competes for Military Contract
© CummingsAerospace.com
As of 2024, the global drone industry was valued at approximately $73 billion, with projections estimating it will surpass $160 billion by 2030 as demand for aerial, maritime, and ground-based uncrewed systems continues to grow across the defense, commercial, agricultural, and logistics sectors. The U.S. drone market is estimated to reach around $10.1 billion in 2025.
Military and homeland security spending accounts for approximately 47% of the U.S. drone sector, underscoring the defense industry’s dominant role in domestic uncrewed systems development. In fiscal year (FY) 2025, the U.S. Department of Defense (DoD) requested $10.1 billion for drone-related acquisition and development, following a peak of $10.95 billion in 2024. These figures reflect the Pentagon’s strategic emphasis on autonomous systems and drone technology as critical components of modern warfare, representing one of the largest individual segments of the global drone economy.
The U.S. is accelerating advancements in military-grade drone development through a combination of bold policy reforms, industrial scaling, and cutting-edge research initiatives. In 2025, the DoD lifted procurement restrictions to allow frontline commanders to directly purchase and test small drones while expanding the Blue UAS program to more rapidly certify U.S.-made systems. Large-scale initiatives, like the Replicator program, are driving the mass production of low-cost, autonomous systems, supported by proposed legislation that allocates billions toward drone manufacturing, autonomy, research and development, and supply chain expansion. Agencies such as DARPA are also leading innovation through programs like Skyborg and REMA, which develop semi-autonomous loyal wingman drones and adaptive systems for operating in contested environments.
One of the most targeted applications of this broader drone strategy is the U.S. Army’s Low Altitude Stalking and Strike Ordnance (LASSO) program, which aims to equip infantry brigades with portable, precision loitering munitions capable of destroying armored threats. Developed under an urgent capability acquisition pathway, LASSO’s first iteration adopts AeroVironment’s Switchblade 600, a tube-launched, portable drone armed with an anti-armor warhead and guided by electro-optical and infrared sensors. With up to 40 minutes of flight time and a range exceeding 20 kilometers, it enables frontline troops to neutralize tanks or fortified positions from a safe distance. Actively competing for inclusion in the LASSO program is Cummings Aerospace with its own loitering munitions drone, the Hellhound S3.
Cummings Aerospace is a Native American woman-owned small business specializing in aerospace engineering solutions. Founded in 2009 by Sheila Cummings, the company is headquartered in Huntsville, Alabama. Cummings, a member of the Lumbee Tribe of North Carolina, holds a bachelor’s degree in aerospace engineering from the University of Maryland and has a background in spacecraft thermal engineering and missile defense systems engineering. Under her leadership, the company has expanded its offerings to include model-based systems engineering, software development, and advanced manufacturing, serving clients such as the DoD.
The Hellhound drone, developed by Cummings Aerospace beginning in 2023, represents a significant leap forward in loitering munition technology. This compact, tube-launched system measures approximately four feet in length and weighs under 25 pounds when fully loaded, making it highly portable for infantry units. Powered by a 3D-printed turbojet engine and fueled by a jet propellant system, the Hellhound can reach speeds exceeding 375 miles per hour, significantly faster than traditional propeller-driven loitering munitions.
Its modular design allows operators to swap payloads, such as precision warheads, electronic warfare packages, or intelligence, surveillance, and reconnaissance (ISR) sensors, without tools and in under five minutes. The drone’s combination of high speed, extended range, and rapid, low-cost production enabled by additive manufacturing sets it apart from other systems and positions it as a highly adaptable option for modern battlefield scenarios.
The Army has requested over $120 million in FY 2025 to expand procurement for the LASSO program, with additional funding allocated for munitions, targeting systems, and operational units through FY 2026. This investment underscores the Army’s commitment to integrating LASSO into both its near-term force structure and long-term modernization strategy, including operational exercises in Europe and alignment with the Pentagon’s Replicator initiative.
As part of this effort, the Hellhound S3 has completed key flight tests and reached Technology Readiness Level 7, demonstrating performance in operationally relevant environments. A formal Request for Proposals is expected to guide the next phase of Army evaluations, with selection announcements anticipated by late 2025 or early 2026. If accepted, Hellhound would bring an ultra-fast, turbojet-powered, 3D-printed capability to the battlefield, reinforcing the U.S. military’s transition toward scalable, decentralized, drone-enabled combat operations.
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