Heavy Air Transport: DARPA Seeks a Drone with Twice Lifting Power of CH-53K King Stallion.

The U.S. Department of Defense, through DARPA (Defense Advanced Research Projects Agency), has recently launched an ambitious project aimed at revolutionizing heavy air transport. This initiative, named "Cost Efficient Cargo," explores the design of an autonomous drone capable of carrying up to 31.75 tons of cargo, which is double the lifting capacity of the CH-53K King Stallion heavy-lift helicopter, currently in service with the U.S. Marine Corps. Unlike the King Stallion, this drone would not be designed for long-range missions but rather for moving heavy loads between ships and beaches or crossing rivers and other natural obstacles inland.

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U.S. Marines with Marine Operational Test and Evaluation Squadron (VMX) 1 transport a Light Armored Vehicle 25 with a CH-53K King Stallion helicopter over Marine Corps Base Camp Lejeune, North Carolina, April 27, 2022 (Picture source: US-DoD)

DARPA recently issued a Request for Information (RFI), seeking innovative proposals for uncrewed heavy-lift systems capable of carrying a 70,000-pound payload (around 35 tons). This RFI specifies that the drone must utilize existing engine and transmission technologies while deviating from systems currently employed by traditional helicopters. The intended operational range for this drone would be 25 miles (40.23 km), flying at an altitude of 500 feet between the cargo pickup point and its destination, with a return trip to the base.

This project is driven by the growing logistical needs of the U.S. military, particularly in high-intensity conflict scenarios against adversaries with significant anti-access/area denial (A2/AD) capabilities, such as China. Amphibious and airborne operations, where troops and equipment must be rapidly moved from sea to land, increasingly face natural or artificial obstacles such as ravines, rivers, or destroyed bridges. Currently, these barriers are often overcome through engineering solutions like floating bridges or amphibious vehicles, but these methods are time-consuming and provide adversaries with the opportunity to mount counterattacks.

The "Cost Efficient Cargo" project aims to address the urgent need for faster and more efficient heavy-lift transport, particularly in scenarios where swift execution is critical to establishing a beachhead or crossing contested areas. Although the CH-53K can lift an impressive 36,000 pounds (16.33 tons), it remains costly, with a unit price of approximately $118 million. Additionally, current solutions, while effective, are limited in range, cost, and vulnerability to enemy defenses.

The CH-53K King Stallion prepares for take-off during sea trials in June 2020 on the USS Wasp (LHD-1) (Picture source: US DoD)

DARPA is considering a variety of configurations for this future heavy-lift drone, including hybrid propulsion systems powered by internal combustion engines, electric motors, or a combination of both. While autonomous capabilities are desired, they are not the immediate focus of this RFI. The main goal is to identify groundbreaking concepts and mitigate risks through scaled-down prototypes before investing in full-scale development.

The war in Ukraine has highlighted the importance of overcoming obstacles and rapidly maneuvering forces, underscoring the vulnerabilities of static infrastructure like temporary bridges, which are often exposed to precision strikes and real-time surveillance. Similarly, in a potential conflict with adversaries like China, U.S. amphibious capabilities could be hampered by anti-ship missiles, limiting the proximity of landing ships to shore. The heavy-lift drone proposed by DARPA is designed to overcome these challenges by facilitating the rapid transfer of cargo from ships at sea to land or across obstacles such as rivers and canyons inland.

The concept includes the possibility of transporting 40-foot ISO containers (12.19 meters) or even armored vehicles like the M2 Bradley. However, while the Bradley's combat weight is approximately 80,000 pounds (36.29 tons), which slightly exceeds the drone’s projected capacity, DARPA anticipates that these vehicles could be transported empty, without ammunition or fuel, reducing their weight.

The logistical challenges facing the U.S. military, particularly in the rapid transport of heavy equipment in contested environments, have prompted the exploration of solutions such as this drone project. DARPA acknowledges that this program could significantly change how the U.S. military deploys its forces and equipment, especially in distributed operations at sea and on land, where flexibility and speed are essential.

While questions remain about the actual efficiency of a fleet of high-lift drones, particularly in terms of cost and their ability to meet operational demand, this project reflects the growing need for innovative logistical solutions in the U.S. armed forces. In the long term, this drone could integrate into the future air mobility ecosystem of the U.S. military, addressing increasingly complex operational requirements.

The "Cost Efficient Cargo" project marks a significant step in the development of the U.S. military’s heavy-lift air transport capabilities. This drone, capable of lifting twice the load of the King Stallion, offers an opportunity to enhance military maneuvers by increasing the speed, flexibility, and resilience of U.S. ground and amphibious forces in the face of increasingly sophisticated adversaries.