Red Cat Adopts AI-Powered 3D Printing for Faster USV Production

Red Cat Holdings is turning to large-scale 3D printing to speed up the production and delivery of its unmanned surface vessels (USVs).

Under a new partnership, Red Cat’s maritime unit Blue Ops will work with Florida-based HADDY to install AI-powered robotic production systems at its facility in Valdosta, Georgia. 

The setup is expected to double manufacturing capacity while shifting away from traditional shipbuilding toward a more flexible, distributed model.

At the core of the effort is a microfactory approach. Instead of relying on centralized production lines, Blue Ops will use robotic 3D printing to design, prototype, and produce vessels on demand, with the ability to scale output across HADDY’s network when required.

The shift is expected to significantly compress development timelines. Blue Ops said the system will allow faster iteration of its five-meter (16-foot) and seven-meter (23-foot) USVs, using AI-driven tools that adapt designs during production.

Blue Ops President Barry Hinckley said the partnership “fundamentally changes how quickly we can move from concept to deployment and gives us the ability to meet demand at scale in ways the industry hasn’t seen before.”

US Defense Expands 3D Printing

Additive manufacturing is gaining traction across the US defense sector, with the Pentagon investing in faster and more flexible production methods.

In April, Stratasys joined a Department of Defense pilot program to validate 3D‑printed components for operational military use, part of a broader push to expand additive manufacturing in defense.

Earlier, in October 2025, HII ordered large metal 3D printers to produce complex ship components for US Navy shipyards, cutting lead times and waste compared with traditional methods.

Two months prior, the US Army partnered with Velo3D and RTX to improve scalable 3D printing processes for defense applications, aiming to produce high-performance components more reliably across multiple sites.

Beyond components, the military is also exploring large-scale applications. 

A 2025 report highlighted US government efforts to use 3D printing in construction, including building facilities faster and at lower cost compared to traditional materials like concrete and steel.