U.S. Marine Corps approves first 3D-printed drone Hanx for unit-level production and combat use.

On January 28, 2026, the 2nd Marine Logistics Group announced that the Hanx, the first Marine-built 3D-printed drone, received flight approval while meeting current NDAA compliance requirements.

On January 28, 2026, the 2nd Marine Logistics Group announced that the Hanx, a Marine-built 3D-printed drone, received flight approval while meeting current NDAA compliance requirements. The program supports Department of Defense objectives to field large quantities of low-cost, expendable unmanned systems by 2028 through decentralized production.
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The Hanx, usable for reconnaissance, logistics support, and one-way attack missions with a reported payload capacity of up to one kilogram, costs roughly $700 per unit, far cheaper than externally sourced drones, often priced below $4,000. (Picture source: 2nd Marine Logistics Group)

The confirmation was issued in the broader context of the U.S. Department of War’s stated objective to acquire up to 300,000 one-way attack drones by calendar year 2028, an objective that emphasizes scale, speed of fielding, and low unit cost. Hanx was identified as a Marine-built system intended to be manufactured, repaired, and modified within Marine units rather than procured solely through external contractors. The program reflects an effort to align small drone availability with anticipated high-consumption operational environments. It also represents a transition from experimental additive-manufacturing initiatives toward systems cleared for operational use. The approval establishes Hanx as the first Marine 3D-printed drone to meet current compliance and flight standards simultaneously.

3D-printed drones offer several operational and logistical advantages that directly address current military requirements. Additive manufacturing allows airframes and structural components to be produced locally within units, reducing reliance on external supply chains and shortening replacement and repair timelines from weeks to days. Design changes can be implemented through updated digital files, supporting rapid iteration, as illustrated by the five major design versions and dozens of incremental adjustments made during the Hanx development cycle. Unit-level production contributes to lower unit costs, allowing higher quantities to be fielded within constrained budgets. Modular architectures allow a single drone to be reconfigured for reconnaissance, logistics, training, and one-way attack roles using the same core structure. When combined with compliant component sourcing, this approach enables scalable, secure, and flexible small drone availability aligned with high-consumption operational scenarios.

The National Defense Authorization Act (NDAA) compliance was presented as a core requirement of the Hanx program, with all critical components selected to avoid restricted-origin hardware and software. This requirement was tied to the need to mitigate risks associated with embedded backdoor functions that could allow unauthorized data access, system monitoring, or remote interference. The Marine Corps contrasted Hanx with earlier internal efforts such as the 2017 “Nibbler” drone, which predated current compliance rules and therefore could not be broadly fielded. By incorporating compliance constraints at the design stage, Hanx was structured to be usable across units without the restrictions applied to non-compliant systems. This approach was intended to ensure that the drone could operate on military networks and in sensitive environments. Compliance was therefore treated as an enabling condition rather than a later modification. The result was a design intended for wider institutional acceptance.

The development of Hanx was led by Sgt. Henry David Volpe, an automotive maintenance technician assigned to 2nd Maintenance Battalion, 2nd Combat Readiness Regiment, within 2nd Marine Logistics Group. Volpe began working with 3D printing in seventh grade and participated in a Lego robotics club during middle school, combining mechanical assembly with programming experience. He later studied automotive maintenance technology in college and worked as a car mechanic, with a stated interest in electronic subsystems. In 2020, disruptions linked to COVID-19 affected both his work and education, prompting him to seek stable employment through military service. He joined the Marine Corps, completed initial training, and finished his military occupational specialty schoolhouse. In 2022, he reported to Camp Lejeune and was assigned as a motor transport mechanic.

While serving with the 2nd Maintenance Battalion, Volpe was introduced to the II Marine Expeditionary Force Innovation Campus, a facility created to train Marines in robotics, additive manufacturing, and production techniques. The campus provides access to 3D printers, design software, and fabrication equipment to support in-house development. Shortly after arriving, Volpe repaired two 3D printers that had halted ongoing activity at the site, restoring basic manufacturing capability. This engagement led to his integration into broader innovation work conducted at the campus. The environment allowed Marines with technical aptitude to pursue projects beyond routine maintenance tasks. It was within this setting that the initial concept for Hanx was developed. The campus functioned as both a training space and a production environment.

Chief Warrant Officer 3 Matthew Pine, the officer in charge of the Innovation Campus, supported the project after reviewing comparable U.S. Army efforts to produce 3D-printed drones. Pine and Volpe traveled to Fort Campbell, Kentucky, where Volpe evaluated an Army-built system and assessed its design and production approach. He concluded that the system involved higher unit costs and relied on external contractors for design and hardware selection. Based on this assessment, Volpe proposed developing a drone that Marines could design, build, and assemble entirely in-house. Pine supported the proposal by guiding development objectives and addressing policy constraints affecting approval pathways. His involvement focused on enabling the project to progress within existing institutional rules. This support was critical to moving the concept beyond an internal prototype.

After returning to Camp Lejeune, Volpe was given a 90-day deadline to produce a viable outcome. He moved from modifying existing drones to designing a system from the ground up using 3D-printed structural components combined with selected compliant electronics. The initial prototype was named Hanx, derived from Volpe’s nickname, and served as the baseline for further refinement. Over the development period, five major design iterations were completed along with dozens of incremental adjustments. Contributions came from multiple Marines, including Cpl Liam Smyth on landing gear design and Staff Sgt Jonathan Borjesson on extended tuning and calibration. Cpl Isauro Vazquezgarcia and Cpl Corven Lacy supported sustained printer operation and design input, while Pine continued to address approval-related policy issues.

Following completion of the prototype phase, the primary challenge shifted to validating component compliance and securing flight approval. Volpe accumulated more than 1,000 hours researching suppliers, contacting manufacturers, and verifying that individual components met NDAA standards. This process required confirming both the origin of parts and their suitability for integration into a compliant system. The assembled drone then had to meet broader approval thresholds applicable to small unmanned aerial systems. Clearance was achieved after the small unmanned aerial systems program office at Naval Air Systems Command implemented interim flight clearance process changes. These changes enabled Hanx to receive authorization to fly. The approval established Hanx as the first Marine-built 3D-printed drone cleared under the current NDAA and naval aviation requirements.

After flight approval, the Innovation Campus began converting the development effort into formal training plans and a draft course framework intended to support replication across the force. The aim was to allow Marines in multiple units to manufacture, repair, and sustain modular drones using similar methods. Hanx was identified as adaptable for reconnaissance, logistics support, and one-way attack missions, with a reported payload capacity of up to one kilogram. The base configuration was cited at a unit cost of roughly $700, compared with externally sourced systems often priced below $4,000 but not open to modification. Marine Corps Special Forces Command at Camp Lejeune moved to adopt the system soon after approval. Explosive ordnance disposal units also indicated plans to acquire about 20 drones, including preparations to integrate explosive payloads, aligning Hanx with broader plans to expand low-cost drone availability ahead of the 2028 acquisition objective.

Written by Jérôme Brahy

Jérôme Brahy is a defense analyst and documentalist at Army Recognition. He specializes in naval modernization, aviation, drones, armored vehicles, and artillery, with a focus on strategic developments in the United States, China, Ukraine, Russia, Türkiye, and Belgium. His analyses go beyond the facts, providing context, identifying key actors, and explaining why defense news matters on a global scale.