First glance at 3D-printed kamikaze drone

The Hellhound S3 kamikaze drone, developed by Cummings Aerospace, has successfully completed flight tests at the US Army Expeditionary Warrior Experiment (AEWE) 2025. The drone is now preparing to compete for the US Army’s upcoming Low Altitude Stalking and Striking Ordnance (LASSO) program, aimed at providing Infantry Brigade Combat Teams (IBCTs) with a long-range, anti-armor capability similar to that of armored brigades.

A key feature of the Hellhound S3 is its extensive use of 3D printing, which enables rapid, cost-effective production and flexible field adaptation. According to the NextGenDefense publication, this manufacturing approach allows for on-demand production and easy fabrication of replacement parts, reducing reliance on traditional supply chains. The drone's modular payload system—which supports warheads, electronic warfare, and intelligence, surveillance, and reconnaissance (ISR) missions—can be swapped out in under five minutes without requiring tools, ensuring versatility in combat scenarios.

With a weight of 11.4 kilograms and speeds exceeding 603 kilometers per hour, the Hellhound S3 offers a significant advantage over traditional quadcopters and propeller-driven drones, which are slower and take longer to reach their targets. In a previous test, it demonstrated a range exceeding 20 kilometers, using only half its fuel capacity. This high-speed performance allows IBCTs to strike targets faster, penetrate deeper into enemy territory, and engage time-sensitive threats more effectively.

Sheila Cummings, CEO of Cummings Aerospace, emphasized the importance of speed in modern combat: “While quadcopters and propeller-driven drones will still be puttering along behind friendly lines, Hellhound will already be over the target area,” she told the publication. The drone’s turbojet propulsion ensures rapid deployment, reducing the risk of enemy countermeasures.

As the LASSO program progresses, Hellhound’s 3D-printed design and modular adaptability will be key selling points, offering a scalable and easily upgradable loitering munition for future battlefield needs. The ability to quickly manufacture components in the field could revolutionize drone warfare, ensuring sustained combat effectiveness even in resource-limited environments.

By Nazrin Sadigova